Numerical Study of Tungsten Cathode Characteristics During TIG Welding

Tungsten Inert Gas (TIG) is widely utilized across various industries. The understanding of tungsten electrode behavior, key component in this process, is vital for optimizing processes and enhancing weld quality. The shape of the electrode tip, influenced by its operational characteristics, significantly impacts the behavior of the electric arc and, consequently, the quality of the welded assembly. This study aims to analyze the influence of current intensity on the thermal and electrical characteristics of the cathode tip during TIG welding, using numerical simulations conducted with Comsol software. The analyses are carried out by applying Direct Current (DC) welding on an aluminum alloy sheet. The results show a similar evolution in the operational characteristics of the electrode as its tip angle varies. In contrast, the current intensity affects only the temperature, which increases with a higher tip angle, while the current density depends solely on the geometry of the electrode tip. The appropriate selection of welding parameters is imperative to preserve the electrode shape and ensure an efficient welding process.