Heliarc welding, tungsten inert gas welding process (TIG welding), or electrode welding process (a carbon arc was commonly employed before), is a technique that is widely used across industries.
However, the process itself of heliarc welding technique can be complex and requires a thorough understanding of the science behind it.
In this article, we will explore the science behind heliarc welding, how it works, the factors that affect its success, and its various applications.
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The basics of inert gas tungsten arc welding
TIG welding is commonly employed to successfully weld lots of different metals, including copper alloys, stainless steel, and titanium alloys.
It is especially well-suited for thin metal sheets that require a correct and controlled welding process.
Types of materials that can be welded with heliarc welding
So, this TIG welding process that we are talking about today is commonly employed to weld a variety of materials, including stainless steel, aluminum, and copper alloys.
Tools and vital equipment required for heliarc welding process
To conduct the TIG welding process, some specific tools and equipment are necessary. A welding torch, a source of electric power, and shielding gas are required for this workmanship process.
The torch that holds the non-consumable electrode and filler wire is connected to the power source, which provides us with the electric current that is necessary to heat and melt the required metal surfaces.
As we already mentioned, TIG welding is the best for welding various metals. Examples are stainless steel, aluminum, and titanium alloys, and are particularly ideal for thin metal sheets or details that require precise, correct, and accurate welding workmanship.
The non-consumable electrode, also the filler wire, the powerful electricity supply, and the shielding gas all work together to make TIG welding a reliable, precise, and accurate welding method for numerous applications.
How TIG welding works
As said before, the TIG welding process always involves a TIG torch (that holds the non-consumable tungsten electrode) and the filler wire.
The TIG torch is connected to the source of electric power. It is known to provide the electric current that we need to heat and melt the metal surfaces to be welded.
The shielding gas can be argon or helium gas, they are the most common in this workmanship. Shielding gas works to protect the weld pool because there is a high risk of atmospheric contamination.
The TIG welding process is, as we’ve already acknowledged, also known as Gas Tungsten Arc Welding (or GTAW).
The heli arc is created by the same electric current that is flowing from the tungsten electrode right to the metal surfaces that need to be welded.
The heat generated by the electrical arc melts the metal surfaces to be welded, which then fuse together when the filler wire is added.
The role of the electrode and filler metal
In TIG welding, first, the electrode and second, the filler metal play important roles in creating a strong and precise weld.
We can pay some attention to each of these components and how they work together in the welding process.
The electrode used in heliarc TIG welding is typically made of tungsten, a dense and durable metal that can withstand high temperatures.
This is important because the tungsten electrode must remain stable and intact during the welding process to provide a steady arc and precise control over the heat input.
The electrode is typically sharpened to a fine point to provide a focused arc for precise welding.
The shape and size of the electrode tip can be varied depending on the specific welding application.
The filler metal is a consumable material that is added to the weld pool to create a strong connection between the two surfaces being joined.
The metal is usually in the form of a wire that is fed into the weld pool by the welder.
The filler metal is chosen based on the type of metal that is being welded, as well as the desired strength and looks of the finished weld.
The filler metal is typically made of the same material as the base metal being welded, but can also be a different metal that is compatible with the base metal.
The filler metal is melted by the heat of the arc and then flows into the weld pool, where it bonds with the base metal to create a strong, durable joint.
The amount of filler metal used depends on the thickness of the base metal and the being used.
Too much filler material can create a weak and brittle weld, while too little filler metal can result in a porous and weak joint.
The goal is to achieve a precise balance between the amount of heat input, the speed of the welding, and the amount of filler metal used to create a strong, reliable weld.
Factors affecting the heliarc welding process
Several factors can affect the quality of the welding workmanship produced by a heliarc welding machine.
These factors include the amperage used, the gas flow rate, and the skill of the welder.
A higher amperage produces more heat and can create deeper welds, while a lower amperage is suitable for thinner materials.
Gas flow rate is also critical, as a higher gas flow rate provides better shielding and prevents contamination, while a lower gas flow rate can lead to porosity and other defects.
Common issues that can occur during heliarc welding
During TIG welding, several common issues can occur in a welding machine, such as porosity, a worn tungsten electrode, cracking, and warping.
Porosity occurs when gas pockets form in the weld due to contamination or insufficient gas shielding.
Cracking and warping can result from excessive welding power heat or uneven welding during this process. A worn tungsten electrode can cause a concave weld puddle.
Techniques for preventing and troubleshooting these issues
Preparing the surfaces to be welded properly, cleaning them of contaminants, and using the correct gas flow rate are crucial for producing high-quality welds.
Proper technique and control of the welding torch and filler wire are also essential, as too much filler wire or improper placement of the torch can lead to defects.
If issues arise during the welding process, troubleshooting techniques can be used to address them.
For example, if porosity occurs, increasing the gas flow rate or cleaning the surfaces more thoroughly can resolve the issue.
If cracking occurs, adjusting the amperage or using smaller filler rods can help prevent further cracking.
Overall, understanding the factors that can affect the quality of the weld and having techniques for preventing and troubleshooting common issues are crucial for successful TIG welding.
Applications of heliarc welding
Heliarc welding has a broad range of applications in various industries.
Heliarc welding career opportunities
It is commonly used in industries that require high-quality and precise welding, such as aerospace and automotive.
In these industries, TIG welding is used to weld aluminum, stainless steel, and other high-performance metals.
It is also used in the construction of critical components such as aircraft fuselage, engine components, and exhaust systems.
In addition to the aerospace and automotive industries, heliarc welding is also used in the manufacturing of medical equipment, bicycles, and custom-made furniture, such as pipeline welding.
Benefits of heliarc welding for various applications
The benefits of heliarc welding for various applications include the ability to produce high-quality welds with minimal distortion, excellent control over the welding process, and the ability to weld various materials.
It can also produce welds with a clean appearance and minimal post-weld cleanup required.
Generally speaking, heliarc welding is a versatile technique that can be used in a wide range of industries and applications.
Safety measures for TIG welding
TIG welding, like any other technique, involves certain risks and hazards that can pose a threat to the welder’s safety, so it’s important to use the appropriate personal protective equipment (PPE) to protect yourself from these risks.
The basic safety gear required for heliarc welding includes a welding helmet, gloves, and a respirator.
The welding helmet protects the eyes and the face from harmful UV radiation and sparks, while the gloves provide protection from burns and cuts.
A respirator is essential for filtering out harmful fumes and particles that are generated during the gas welding process.
Specific safety gear required for welding different materials
In addition to these basic safety gear requirements, specific safety gear may be required for welding different materials.
For example, welding aluminum requires a specialized helmet with a wider shade range, as well as gloves made from non-flammable material.
Stainless steel welding may require a different type of respirator with a higher filtration capacity.
It’s important to consult the manufacturer’s recommendations and safety guidelines when selecting appropriate safety gear for heliarc welding.
Safety precautions and best practices
Proper ventilation is key to minimizing exposure to hazardous fumes and particles generated during the welding process.
Welders should work in well-ventilated areas or use local exhaust ventilation systems to remove contaminants from the work area.
Additionally, it’s essential to keep the workspace organized and free of clutter to avoid tripping hazards or accidental exposure to hazardous materials.
Regular equipment maintenance is essential for ensuring safe and successful welding. Welders should regularly inspect their equipment for damage or wear and tear and perform any necessary repairs or replacements.
Safe handling of materials is also crucial to prevent injuries. Materials should be stored and transported properly, and welders should use caution when handling hot or sharp objects.
There are also safety certifications and training programs available for TIG welders to further enhance their knowledge and skills in welding safety.
Organizations such as the American Welding Society offer certification programs that demonstrate a welder’s proficiency in safe welding practices.
By following these safety precautions and best practices, TIG welders can minimize the risks associated with welding and ensure a safe and successful welding experience.
Conclusion
In conclusion, TIG welding is a versatile welding technique used in a range of industries that require precise and high-quality welds.
Frequently asked questions
To further understand TIG welding and its various applications, it’s important to address common questions that individuals may have about the TIG welding technique.
What is heliarc welding?
Tungsten Inert Gas (TIG) welding, also called heliarc welding, is a welding technique that utilizes a non-consumable tungsten electrode and shielding gas to create a precise and superior-quality weld.
What’s the difference between TIG and heliarc welding?
Heliarc welding or TIG shielding gas welding, are the same things. TIG welding is the more modern term commonly used to name/describe the welding process that was previously known as heliarc welding.
Why is it called heliarc welding?
The term “heliarc” comes from “helium arc welding,” which was the first name given to the TIG welding process.
Later, the term was replaced with “tungsten inert gas” welding, but “heliarc” is still often used as a synonym for TIG welding.
How does heliarc work?
Heliarc technique of welding works by creating the direct current electrode negative polarity with the help of tungsten electrodes.
The heliarc or TIG welding process involves an electric arc, a TIG torch (to hold the non-consumable tungsten electrodes), and the filler material.
The TIG torch connects to a source of electric power that provides the electric current that we need for heating and melting the metal surfaces to be welded.
What is MIG welding?
Gas Metal Arc Welding (GMAW), usually called MIG welding, is a welding process that employs a spool of wire that is being fed as the electrode, and an inert gas (for example, helium or argon) to shield the pool from contamination from the atmosphere.
Learn More About: Heliarc Welding