Identification of the Dominant Factor for Droplet Ejection from a Tungsten Electrode during AC Tungsten Inert Gas Welding by Visualisation of Electrode Phenomena

Droplet ejections from a molten tungsten electrode during alternating current tungsten inert gas (AC TIG) welding were observed successfully by a high-speed video captured at 75,000 fps. The welding conditions and timings that were likely to occur were investigated. The electrode surface temperature was also measured. A crater was formed on the surface of the electrode, and a droplet ejection occurred following the separation of the tip of the ridge growing from the centre of the crater. A series of droplet ejections occurred on a time scale of approximately 0.4 ms. Our results showed that the high temperature of the electrode surface was the common factor for droplet ejections. The dominant force for droplet ejection was discussed by estimating the balance of forces acting on the molten electrode surface. The pressure due to surface tension was the largest pressure at any time during the AC cycle, which decreased in the second half of the EP period. Our findings suggest that the surface tension was the dominant force for changing the electrode shape and that droplet ejections occurred when the surface tension decreased due to the increase in the electrode surface temperature.