Heliarc welders, commonly known as TIG welders, are a specialist welder type using arc welding and inert gas shields to offer high-quality, precise welding. These popular welders remain at the top of the welding game.
This article will cover everything retailers need to know about Heliarc welders, so that you can ensure you add the best options to your inventory for more sales in 2025!
Table of Contents
What is Heliarc welding?
Is Heliarc welding the same as TIG welding?
Components of a Heliarc/TIG welder
How does Heliarc/TIG welding work?
What materials can be welded with Heliarc/TIG welders?
What kind of joint configurations can be achieved with a Heliarc/TIG welder?
Advantages of Heliarc/TIG welders
Disadvantages of Heliarc/TIG welders
Applications of Heliarc/TIG welding
Maintenance and troubleshooting for Heliarc/TIG welders
Conclusion
What is Heliarc welding?
Heliarc welding is a process that uses non-consumable tungsten electrodes to generate enough heat to arc weld, while also using an inert gas, usually helium or argon, to create a protective shield over the weld area and so protect it from atmospheric contamination. Heliarc welding is well-known for its precision and clean welds, making it a popular choice for high-quality welds on a wide range of materials. Heliarc welding is also referred to as Gas Tungsten Arc Welding (GTAW) or Tungsten Inert Gas (TIG) welding.
Is Heliarc welding the same as TIG welding?
Although considered the same thing today, Heliarc welding was originally developed in the 1930s as a type of arc welding that exclusively used helium (hence the name “Heliarc”) as its protective inert shielding gas. Originally created to weld aluminum and magnesium for military aircraft, it gained popularity during WWII and soon evolved to weld a greater variety of metals, including stainless steel, copper, and titanium. Following the war, it further evolved to embrace argon as its protective inert shielding gas, and so it became known under its new names of TIG or GTAW welding, with TIG welding being the most commonly-used term.
Components of a Heliarc/TIG welder
A Heliarc or TIG welder has many of the same components as a traditional welder, however, this welder separates the electrode and filler metal rod (known as the TIG rod), whereas other welders, like the Metal Inert Gas (MIG) welder, have them together. The main components of a Heliarc welder are:
Power source
The power source for the Heliarc welder is the source of the electrical energy that generates the arc between the tungsten electrode and the welding material. The power source can be either AC or DC, however, the current must be adjustable in order to control the heat of the weld. This allows for the welding of different materials.
Torch and electrode
The welding torch channels both the electrical current (non-consumable tungsten electrode) and the inert gas to create both the welding arc and the protective shield. It works alongside the TIG rod, which is made up of the filler metal.
Shielding gas supply
The inert shielding gas transferred through the torch is supplied by a tank of shielding gas, usually helium, argon, or a mixture of both. It serves the purpose of protecting the weld site from oxidation and atmospheric contamination during the welding process.
Cooling system
Due to the extreme heat created by the tungsten electrode, many Heliarc welding torches use a cooling system to maintain a quality weld and consistent performance from the welder. This cooling system can either be formed through air cooling or liquid cooling, depending on the intensity of the project.
Control panel and settings
As a high-quality welder, Heliarc welders offer an easy-to-use control panel for gas flow, pulse parameter, and amperage adjustments. This gives the welding operator control over the settings allowing for changes to cater to different welding materials.
How does Heliarc/TIG welding work?
In Heliarc welding, the arc created by the tungsten electrode and the material being welded generates intense heat and begins to melt the base material. The TIG rod is melted alongside to add more filler metal and so create a stronger bond. During this process, the shielding gas flows over the welding area and uses pressure to blow any other gasses and materials away from the joint and so keep it clean. The welder manipulates the heated torch to create a strong, smooth, and defect-free joint.
What materials can be welded with Heliarc/TIG welders?
Although initially used for aluminum and magnesium, under their new identity as TIG welders, Heliarc welders have become much more versatile. Heliarc welders now weld aluminum, stainless steel, copper, titanium, and nickel alloys, making it an ideal welder for industries that require untarnished welds across a variety of metals.
What kind of joint configurations can be achieved with a Heliarc/TIG welder?
In addition to its versatility in metal types, Heliarc welders are able to support several joint configurations. These include lap joints, butt joints, T-joints, and corner joints, allowing for a great variety of applications, structural requirements and material thickness.
Advantages of Heliarc/TIG welders
In addition to great versatility in materials and joint configurations, there are many advantages to using a Heliarc welder.
Precision and control
Precision and control are two of the key advantages to using a Heliarc welder. Thanks to the ease with which the operator can maneuver the torch, and thus the arc, they can easily control where the weld takes place.
Clean and high-quality welds
The shielding gas ensures that the welding area remains clean during the weld, while the non-consumable tungsten electrode creates a smooth and high-quality joint. This makes Heliarc welders a leading welder for clean and high-quality welds.
Low distortion pieces
The ability to control the power source to monitor the heat output, as well as the ability to easily bend the arc to target certain areas reduces the chance of thermal distortion on the weld. This leads to aesthetically pleasing welds and less post-weld cleanup.
Disadvantages of Heliarc/TIG welders
It seems that the Heliarc welder offers it all, but like any tool, it has its disadvantages too.
Solder welding speed
One of the main advantages of Heliarc welding — its precise and clean welds — is also one of its disadvantages. Heliarc welding requires skill and high levels of manipulation and concentration, making it a slower welding process than other methods, such as MIG or stick welding. This makes it unsuitable for large-scale manufacturing or welding where speed is a factor.
Skill and training requirements
Proper manipulation of the arc, including the correct length and target, as well as the need to control two components — the torch and filler material — requires years of practice and a steady hand. As a result, businesses need to invest more in training or hire skilled welders at a higher cost to them.
Equipment cost
The Heliarc welder itself, as well as the power source and shielding gas supplies can be quite expensive. In addition, these components require proper maintenance to ensure proper functionality — all of which means additional operational costs.
Limited thickness capacity
Heliarc welding is best suited to welding thinner materials, with thicker materials often requiring multiple passes and thus additional energy and gas consumption.
Gas supply and shielding issues
The use of gas to shield the weld area can be compromised if there is an insufficient gas supply, an issue with distribution, or if the weld is being carried out outdoors, where wind can disrupt the gas coverage. This makes Heliarc welding a complex welding process that must be carried out in specific areas and conditions.
Applications of Heliarc/TIG welding
Heliarc welding is used in many industries, as well as by hobbyists and DIY welders.
Aerospace industries
As per its original usage, Heliarc welders continue to be used on aircraft and other aerospace vehicles and tools. Here, they are predominantly used for the fabrication of aircraft components in aluminum or titanium thanks to their high-precision welds that ensure structural integrity and performance.
Automotive sector
In the automotive sector, the Heliarc welder’s ability to weld thin materials with minimal distortion stands out. Here, it is used to weld components including exhaust pipes, chassis parts, and roll carriages.
Manufacturing and fabrication
Within manufacturing and fabrication, Heliarc welders are used to produce high-quality, durable joints, while its versatility allows it to be used across a whole range of components. However, due to its slower welding ability, Heliarc welding is not the core welding type used in these industries.
Sculptural and artistic applications
Metalwork hobbyists and artists favor Heliarc welders thanks to its ability to work with great precision to create intricate patterns and designs that are strong and durable.
Maintenance and troubleshooting for Heliarc/TIG welders
To ensure continuous and precise welding from a Heliarc welder, it’s important to carry out proper maintenance. This includes inspecting the torch and electrode for wear and replacing the electrodes when worn, checking the gas hose for leaks and adjusting the gas flow when necessary, and ensuring that the cooling system is in proper working order.
By carrying out these regular checks, properly storing the welder, and ensuring that the workpiece is properly prepared and cleaned before starting a weld, a Heliarc welder owner can not only avoid common issues, such as arc instability, poor shielding gas coverage, and electrode contamination, but they can also extend the lifespan of the welder.
Conclusion
Heliarc welders, or TIG welders, are precise and versatile welders that stand out against the competition thanks to the cleanliness, smoothness, and quality of their welds. These welders ensure great precision and structural integrity, to the point that they are a preferred choice for industries with very high requirements, such as aerospace engineering. Heliarc welders are best suited for thinner metals, such as aluminum and titanium, but can be used across a great variety of materials and to create many joint types. The future of these welders continues to be bright in industries that require quality over speed.
