TIG Welding Best Practices
TIG welding or Gas Tungsten Arc Welding (GTAW) is a precise welding process for making clean welds. Using a non consumable tungsten electrode and an inert gas like argon it’s got more control and better welds than gas metal arc welding.
In this article we’ll cover TIG welding basics, components, comparisons, setup, safety, advanced techniques and applications in aerospace and automotive.
Key takeaways
TIG welding uses a non-consumable tungsten electrode and an inert gas to make clean welds, for things like space vehicles.
Setting up a TIG welder isn’t rocket science but good luck getting it right on the first try without fusing your electrode to your workpiece – because that’s just so much fun.
If you want clean welds you better treat your welder like a diva: regular maintenance and no tungsten contamination or you’ll end up with a hot mess instead of a masterpiece.
TIG Welding Basics
Before you get started you need to understand the basics. TIG welding or Gas Tungsten Arc Welding (GTAW) uses a non consumable tungsten electrode to make welds. This process is highly regarded for its high quality welds and control, so it’s the go to process for exacting welders. A good tig weld requires a high level of skill and precision so you need to understand the process.
In TIG welding the tungsten electrode is key. It maintains its integrity during welding which allows for a consistent arc and enough heat to melt the base material. An inert gas like argon or helium protects the weld zone from atmospheric contaminants so you get clean welds.
But TIG welding requires a lot of skill and coordination – it’s like playing Call of Duty, where every precise action can lead to a clutch win or a frustrating defeat.
What is TIG Welding?
Using tungsten inert gas a TIG welder fuses metals together with precision and control. Understanding TIG welding basics is key to making a good TIG weld including forming a good weld bead. This process uses a non consumable tungsten electrode that maintains a consistent arc and supplies enough heat to melt the base material without wearing out.
An inert gas – usually argon – is used during welding to shield the weld pool from atmospheric contaminants, fewer defects and no spatter. Igniting an arc with a TIG machine can get up to 11,000°F, that’s a lot of heat for the process and metal inert gas makes the welding operation more efficient.
Known as GTAW (Gas Tungsten Arc Welding) this process can work with aluminum, copper and some steel types across various applications. From making jewelry to building components for space vehicles – TIG can do both delicate and heavy work.
Getting proficient in TIG welding is a lot of fun. Nothing is better looking at your TIG weld and thinking: that weld looks amazing. I urge you to practice so you can experience that feeling at least once in your life.
TIG Welder Components
Breaking it down to the basics a TIG (Tungsten Inert Gas) welder has the following components: welding torch, electrode, shielding gas, electrical power source and either a foot pedal or manual hand control. The heart of this setup is the tungsten electrode inside the torch. It’s the key to the consistent arc that’s so important.
You need a constant current power source in TIG welding to maintain the current throughout the welding process. A wrong power source can melt back the electrode tip or fuse the electrode to the workpiece – not good! Variable amperage can be adjusted with what seems like an extra device: the foot pedal. If you want full control over your weld pool, you need to be using a foot pedal while sitting at a workbench.
As for shielding gas – argon does its job perfectly when fed through tubing up to where it meets our trusty tungsten friend at his ceramic cup home. This shield protects our precious weld pool from airborne contaminants that can compromise quality and integrity. Getting the gas flow right is important too. You’ll usually set your dial between 15-20 cubic feet per hour (cfh) depending on your project. In the aerospace industry, you will be using a whopping 50-70 cfh!
How TIG Welding Works
Getting into the nitty gritty of TIG welding this process starts when an arc is struck by bringing the tungsten electrode in contact with the workpiece. The heat from the electric arc melts the base metal and any filler material, resulting in a molten weld pool and forming a weld bead.
A sharp tungsten electrode is best for making precise and good welds. To prevent overheating – which can melt – the electrode runs on direct current (DC) with negative polarity. This setup maintains the arc stability and gives uniform weld quality.
Depending on what you’re welding together you may need to adjust these settings. For example aluminum welding requires alternating current (AC) whereas steel requires DC power supply – showing how versatile TIG welding is for different projects or applications.
TIG Welding vs Other Methods
Comparing TIG welding to other welding methods is like comparing a fine wine to a cheap beer. Both get the job done but the former does it with class. TIG welding is known for its precision and versatility and can work with many materials and thicknesses.
Compared to MIG and stick welding TIG is more precise and better quality. Compared to gas metal arc welding TIG has more control and higher quality welds because of the non-consumable tungsten electrode and inert gases, resulting to a cleaner and more precise weld bead, showing its complexity and advantages in weld strength and quality.
TIG vs MIG
In TIG welding a non-consumable tungsten electrode is used to create the welding arc. In MIG welding a wire is used that is both the filler material and consumed in the process.
TIG welding takes more time and requires more skill than MIG welding but gives better quality. The welds made with TIG are cleaner and more visually pleasing with less defects. So for those who want perfection in their work TIG is the way to go.
TIG vs Stick Welding
Shielded Metal Arc Welding (stick welding) uses consumable electrodes and has less precision during the welding process compared to TIG (Tungsten Inert Gas) welding. TIG uses a non-consumable tungsten electrode which gives more control over heat input and minimal distortion in the weld joint. This makes TIG welding better for applications that require high accuracy and clean welds.
Stick welding can have a wider heat affected zone due to heat application and can result to temperature irregularities in the material being welded. Although it can achieve deep penetration for heavy applications TIG is more consistent. It produces cleaner welds with less contamination.
Getting Started with TIG Welding
Ready to start TIG welding? You need to set up your TIG welder and learn the basics.
In this section we’ll guide you on how to set up your TIG welder, the primary methods of welding and the safety precautions to get you started.
Setting Up Your TIG Machine
Setting up a TIG welder is easy. You need a welding torch and a constant current power source that can be adjusted for direct current (DC) or alternating current (AC) depending on the material you’re welding. For aluminum welding set your welder to AC polarity.
For TIG welding 100% argon is the best and most effective shielding gas for most metals. For most welding applications set the gas flow rate to 15-20 cubic feet per hour, though this varies depending on the cup size on your tig torch and the alloy of metal you are TIG welding.
When preparing your tungsten electrode for welding make sure the stickout (how far it extends from the ceramic cup) is equal to the diameter of the cup itself.
Basic TIG Welding Techniques
Maintain Torch Height
For better quality welds basic techniques are important. The tungsten should be 1/16 to 1/8 inch above the workpiece to maintain the arc length and position the TIG torch at 70-80 degrees from the workpiece for better results.
If you can implement this into your bag of techniques, you officially overcame the biggest hurdle in learning TIG welding.
Do Not Overheat
Pulsed welding can help in controlling heat input. Add filler rod metal into the weld puddle methodically and not too much at once. But don’t rely on this technique as it is only required when welding really thin metals. It’s main purpose is to prevent the metal from what I call “peeling away” from one another. Aka; prevent opening a keyhole in your welding joint.
Prep and Clean Your Metal
For clean and visually pleasing results both base metals and filler materials should be cleaned before welding. Wipe them down with acetone until they are free of all that black gunk. Don’t be lazy because cleanliness is so important for amazing TIG welds.
Safety
Safety first! Proper protective gear is a must in TIG welding to prevent injuries and health risks. Long-sleeved shirt or coveralls, welding helmet, leather gloves and shoes.
Welders can be exposed to ozone and nitric oxides which can cause lung damage and other respiratory problems and skin damage from UV light exposure. Wear protective clothing, opaque helmet with dark eye lenses and use transparent welding curtains to shield from UV light exposure.
Advanced TIG Welding Tips
Want to improve your TIG welding skills? By mastering advanced techniques you can increase your efficiency and weld quality.
Here we’ll give you tips on how to avoid tungsten contamination, control heat input during welding and improve your weld appearance.
Tungsten Contamination
To get good weld quality and no defects you must avoid contamination from the weld bead and tungsten. If the tungsten touches the workpiece it must be removed and either cleaned or reformed.
If you’re welding something in your garage leave it. It doesn’t matter. But if you are a professional TIG welder in the aerospace industry, you better grind out the tungsten inclusion. The x-ray technicians will find it and you will be exposed as a noob who stuck the tungsten and was too lazy to dig out.
Heat Input
Heat input is important to maintain weld integrity and appearance. Adjusting the amperage with foot pedal gives better heat control. Too much heat can cause weld discoloration and stainless steel can be affected, adjust the amperage to mitigate this.
Craters at the end of the weld can cause cracking which can be avoided by reducing current gradually while adding filler metal. Adjusting the electrode positive and negative balance when welding aluminum helps in heat input and weld quality.
Weld Appearance
A clean environment is important to produce welds that are not only visually pleasing but high quality. Lower currents require smaller diameter electrodes and finer tip angles to have better control of the weld pool.
I suggest doing a visual weld inspection before walking away from the weld. Check for oxidation, overlap, undercut, cracks, and craters. These welding discontinuities are issues with your technique.
Oxidation? You pulled away your torch too fast and didn’t let the post-flow shield the hot weld from the atmosphere.
Overlap? You suck at hand-feeding wire and/or your amperage was too low.
Crater? You terminate the arc too fast and your weld self-destructed.
You want to be a good welder cause they make the big bucks. Good welders do not leave these preventable and entirely skill-based welding issues on their welds.
Applications and Materials
This section covers the materials used in TIG welding and its applications in different industries, TIG welding is known for its quality and visual appeal that’s why it’s used in critical applications.
TIG Welding Materials
Use the right filler material when TIG welding materials like aluminum, stainless steel, magnesium, titanium and 4130 chrome-moly steel to get strong and visually pleasing welds.
My favorite metals to TIG weld has got to be the exotic alloys. Titanium is the most fun to weld. It’s shiny, sticky, and light. Welding titanium means you have to be strict with your torch angle because you need to monitor where you direct the shielding gas or your weld will turn flaky and white like dandruff.
Industry Applications
Aerospace Welding
Aerospace industry relies heavily on TIG welding for its precision and ability to join thin materials. When building parts for aircraft and spacecraft TIG weld quality is critical.
The American Welding Society (AWS) wrote the highest-level industry standard called the AWS D17.1 codebook. This codebook has the strictest requirements of TIG welding out there. Which is a good thing because aerospace welders build rockets.
Automotive Welding
The automotive industry also uses TIG welding widely because of its ability to produce strong, clean welds on various metals. This process is used from chassis frame construction to engine part assembly to ensure longevity and performance. Automotive TIG welders are pretty damn skilled, too. Have you ever seen those elaborate Ferrari exhaust systems?
TIG Welding Bike Frames
Lastly, TIG welding is highly prized in bicycle manufacturing because it gives strong joints and neat finish. The accuracy of this process ensures that bike frames are not only durable but visually pleasing making it the preferred process in this industry.
TIG Welder and Mig Welder Maintenance and Troubleshooting
Your TIG welder and mig welder needs maintenance to stay in top condition. Regular maintenance and troubleshooting common issues will save you a lot of headaches later on.
Maintenance
To maintain the performance and extend the life of your TIG welder, you must do regular maintenance. Cleaning the TIG torch and welding torch is important to avoid contamination that can affect welding. Check gas lines for leaks to ensure proper shielding during welding.
Keep your welding machine dust and debris free to prevent breakdowns. Regular checks will help you detect minor issues before they become major problems with your welder.
Troubleshooting
Common issues with TIG welding are arc start difficulties, high spatter and contamination in the weld. These problems can be caused by low gas flow or impurities on the tungsten electrode. To fix arc start instability check your tungsten is sharpened correctly and make sure there’s enough gas flow.
When spatter occurs during TIG welding it may be due to machine settings not adjusted properly. Weld contamination is another issue that can be caused by wrong gas flow rates or leaks in the system resulting to inadequate shielding gas coverage.
Before use always inspect all connectors and leads for safe welding.
Conclusion
TIG welding or Gas Tungsten Arc welding is known for its precision, versatility and quality of welds. From the basics to setting up your TIG machine to advanced techniques and maintenance this guide has got you covered to become a TIG welding pro.
Remember practice makes perfect. Keep practicing, maintain your equipment and always safety first. With dedication and the right techniques your TIG welds will not only be strong but a work of art. Happy welding!
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FAQs
What’s the common filler rod for welding aluminum?
The usual filler rod everyone uses for aluminum: 4043 or 6061 alloy. It always depends on the alloy of your base metal. But chances are these two alloys are what you want to use.
What’s the safety gear to wear when TIG welding?
The least amount of personal protective equipment you need is: a welding helmet, long-sleeved shirt and leather gloves.
What to do if the tungsten touches the workpiece during TIG welding?
Just remove that pesky tungsten and give it a little makeover—because nothing says “professional welder” like a little tungsten drama during your TIG welding.
Clean it up and reshape it; it’s like a spa day for your tungsten!
What’s the max thickness a good TIG machine can weld for aluminum and steel?
Oh, only 1/4-inch for aluminum and 3/8-inch for steel? This is what I would expect from a good machine. However, you want to run a water-cooled torch if you are welding thick metal.
What is Gas Tungsten Arc Welding (GTAW)?
The same as TIG except saying G-TAW is more fun.
