Welding methods and equipment have evolved over the years with advancements in human lifestyles and environmental needs. Among these, Conventional Gas Tungsten Inert Gas (C-TIG) Welding stands out because of its specialized applications and is recognized for its importance in manufacturing. However, the low depth of penetration (DOP) in thick sheet metals has necessitated the development of assisted methods, such as activating uxes in the Activated TIG (A-TIG) process. This study conducts a comparative sustainability analysis of A-TIG and C-TIG welding processes. A-TIG utilizes a TiO₂-based ux to enhance weld penetration. A Life Cycle Assessment (LCA) was performed using the Ecoinvent 3 database and EPD 2018 and ReCiPe 2016 Endpoint (H) methodologies. Results indicate that A-TIG exhibits higher impacts in photochemical oxidation and water scarcity due to TiO₂ ux preparation and methanol usage. C-TIG shows higher impacts in acidication, eutrophication, global warming potential (GWP), abiotic depletion of elements (ADE), abiotic depletion of fossil fuels (ADF), and ozone layer depletion because its energy-intensive nature requires 70% more electricity. Endpoint modeling identies human health as the most affected category, with C-TIG contributing 62% more damage due to emissions and energy use. Despite A-TIG’s improved energy eciency and weld quality, its ux reliance introduces specic environmental trade-offs. This research highlights the need to balance weld quality and ecological sustainability for greener manufacturing practices.

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