TIG welding is one of the most precise welding methods out there. If you’ve ever seen a clean, professional-looking weld with a smooth finish, chances are it was done using TIG. Unlike other welding processes, TIG (Tungsten Inert Gas) welding gives you complete control over the weld, making it perfect for thin materials, stainless steel, and aluminum.
It takes patience and practice, but once you get the hang of it, you can create high-quality welds that look great and last a long time.
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If you’re just starting or want to improve your skills, understanding basic TIG welding techniques is essential. Let’s dive into the fundamentals, from setting up your equipment to perfecting your hand movements.
Setting Up Your TIG Welder
The first step to successful TIG welding is setting up your welder correctly. Each component plays a crucial role in how well your welds turn out.
Choosing the Right Tungsten Electrode
TIG welding uses a non-consumable tungsten electrode, which means the electrode doesn’t melt into the weld like it does in stick or MIG welding. It creates an arc that melts the base metal and filler rod. Choosing the right tungsten type depends on the material you’re welding.
| Tungsten Type | Color Code | Best For |
|---|---|---|
| Pure Tungsten | Green | Aluminum (AC) |
| 2% Thoriated | Red | Steel & Stainless Steel (DC) |
| 2% Lanthanated | Blue | Aluminum & Steel (AC/DC) |
| 1.5% Ceriated | Grey | Low-amperage applications |
For beginners, 2% Thoriated (red) tungsten is a good choice for steel, while 2% Lanthanated (blue) works well for both aluminum and steel.
Selecting the Right Shielding Gas
Shielding gas is what protects your weld from contamination. For most TIG welding applications, argon is the best choice because it provides a stable arc and smooth welds.
- 100% Argon – Ideal for most TIG welding jobs.
- Argon/Helium Mix – Adds more heat for thick materials.
If you’re welding aluminum, using an argon-helium mix can help with penetration. For stainless steel, stick with 100% argon.
Adjusting Amperage and Polarity
Your amperage setting depends on the thickness of the metal. Here’s a simple guide:
| Metal Thickness | Amperage (Approx.) |
|---|---|
| 1/16″ (1.6mm) | 40-70A |
| 1/8″ (3.2mm) | 80-120A |
| 1/4″ (6.4mm) | 140-200A |
For steel and stainless steel, use DCEN (Direct Current Electrode Negative). For aluminum, use AC (Alternating Current) because it helps break up the oxide layer on the surface.
Mastering Torch Control
Holding the torch correctly is essential for TIG welding. A steady hand makes all the difference between a good weld and a messy one.
Torch Grip
Hold the torch like a pencil for better control. Your hand should be steady but relaxed. If needed, rest your hand on the workpiece or a welding table to stabilize your movement.
Torch Angle
Maintain a 10-15 degree angle between the torch and the workpiece. Keeping the right angle helps direct the arc and prevents contamination from touching the tungsten to the metal.
Proper Filler Rod Technique
TIG welding is unique because it requires feeding the filler rod manually. This technique takes practice, but once you master it, your welds will improve significantly.
Holding the Filler Rod
Hold the filler rod in your non-dominant hand and feed it smoothly into the puddle. Avoid dipping it too close to the tungsten, or you’ll get contamination.
Dabbing Method
The best way to add filler metal is by using the dabbing technique. Move the rod into the molten pool, then quickly pull it back out. This keeps the weld even and prevents excess material buildup.
Controlling Heat and Travel Speed
TIG welding requires precise heat control. Too much heat will warp the metal, while too little heat won’t create a strong weld.
Pulse Welding
Many TIG welders have a pulse feature, which helps control heat input. Pulsing alternates between high and low current, preventing overheating and improving control over thin materials.
Travel Speed
A steady, consistent movement is key. If you move too fast, the weld won’t fuse properly. If you move too slow, you’ll overheat the metal and create burn-through.
Avoiding Common TIG Welding Mistakes
TIG welding can be tricky, and mistakes happen. Here’s how to avoid the most common ones:
- Tungsten Contamination – If your tungsten touches the workpiece, grind it clean before continuing.
- Porosity in the Weld – Ensure proper gas coverage and avoid drafts that can blow away shielding gas.
- Inconsistent Bead Appearance – Maintain a steady hand and even filler rod dabs.
Practicing TIG Welding
Practice makes perfect. Start on scrap metal before working on actual projects. Here are a few drills to improve your technique:
- Straight Line Beads – Run a bead without filler metal to focus on arc control.
- Circle Motion Drills – Practice small, even circles to refine movement.
- Lap and T-Joint Welds – Work on different joint configurations to build versatility.
Conclusion
TIG welding is an art that takes patience, but once you get the basics down, it opens up a world of possibilities. From choosing the right tungsten to controlling the filler rod and heat, every step contributes to creating strong, clean welds.
If you’re just starting, don’t rush—practice on scrap metal, get comfortable with your torch, and refine your hand movements. You’ll develop the skill and confidence to tackle any welding project with precision and control.
Frequently Asked Questions
What is the best tungsten for TIG welding steel?
2% Thoriated (red) tungsten is the best choice for welding steel.
What gas is best for TIG welding aluminum?
100% Argon or an Argon/Helium mix works best for aluminum.
How can I prevent tungsten contamination?
Avoid touching the tungsten to the workpiece and keep it clean by grinding it to a sharp point.
Why is my TIG weld full of holes?
Porosity is usually caused by inadequate gas coverage. Check for leaks and ensure there’s no draft affecting the shielding gas.
Can I TIG weld without filler rod?
Yes, if the metal edges are clean and fit tightly, you can fuse them without filler using an autogenous weld.
