The Ultimate TIG Welding Guide

3. The TIG Welding Process: Step-by-Step Guide

Mastering TIG welding requires attention to detail, precision, and the right technique. Unlike other welding methods, TIG welding demands steady hands, proper heat control, and a deep understanding of material behavior. This section will walk you through the step-by-step process of TIG welding, from setting up your welder to post-weld inspection. We'll also highlight common mistakes and how to avoid them to ensure professional-quality welds.

Step 1: Setting Up Your TIG Welder

Before striking an arc, it's essential to configure your TIG welder settings correctly. Here's what you need to do:

Select AC or DC Mode

• Use AC for aluminum and magnesium.

• Use DC for steel, stainless steel, titanium, and copper.

Set Amperage

• Lower amperage for thin materials (e.g., 50–100A for sheet metal).

• Higher amperage for thicker materials (e.g., 150–250A for structural steel).

• If using a foot pedal, start with a higher setting and adjust as needed.

Adjust Shielding Gas Flow

• Argon is the most common choice (10–20 CFH flow rate).

• Use a gas lens to ensure better shielding and reduce turbulence.

Choose Your Tungsten Electrode

• 2% Thoriated (Red): Best for DC welding (steel, stainless, titanium).

• 1.5% Lanthanated (Gold): A great all-around choice for both AC and DC.

• Pure Tungsten (Green): Ideal for AC welding (aluminum, magnesium).

Step 2: Preparing the Workpiece

A clean surface is crucial for a strong, defect-free weld. Follow these steps to ensure proper preparation:

• Remove Contaminants: Use a stainless steel brush or acetone to clean the weld area. Oil, grease, rust, and oxidation can ruin your weld.

• Fit-Up & Clamping: Ensure the pieces are properly aligned and secured using clamps, magnets, or tack welds. Gaps or misalignment can weaken the joint.

• Use a Backing Plate (if needed): Helps prevent burn-through on thin materials.

Pro Tip: For aluminum welding, always remove the oxide layer with a dedicated stainless steel brush before welding.

Step 3: Striking an Arc & Maintaining a Stable Puddle

Striking an Arc

• Use a high-frequency (HF) start to ignite the arc without touching the tungsten to the workpiece.

• If using lift-arc start, touch the tungsten to the metal briefly and lift it to initiate the arc.

• Keep the tungsten electrode about 1/8 inch from the workpiece to maintain a stable arc.

Maintaining the Weld Pool (Puddle)

Once the arc is stable, focus on controlling the heat input:

• The molten metal pool should be bright and fluid but not too large.

• If the puddle is too small, increase amperage slightly or hold the arc longer.

• If the puddle is too large, reduce heat or move faster.

Pro Tip: Do not dip the tungsten in the puddle! Tungsten contamination will ruin the weld and require regrinding the electrode.

Step 4: Adding Filler Metal & Controlling Heat Input

• Hold the filler rod at a 15–20° angle to the workpiece.

• Dip the filler rod into the leading edge of the puddle without touching the tungsten.

• Feed the filler smoothly while maintaining a steady travel speed.

• Use a foot pedal (if available) to adjust amperage and fine-tune heat input.

Pro Tip: For thin materials, pulse welding (alternating high and low amperage) helps prevent burn-through.

Step 5: Controlling Travel Speed for Consistent Bead Formation

• Move the torch at a consistent speed to ensure even bead width.

• Keep the arc length short (about 1/8 inch) for a concentrated, controlled weld.

• Watch for undercutting (moving too fast) or excessive buildup (moving too slow).

Pro Tip: For aluminum welding, use a "stacked dimes" technique by pulsing the torch forward slightly after each filler addition.

Step 6: Post-Weld Cleaning & Inspection

Once the weld is complete, proper finishing ensures strong, clean welds:

• Remove Oxidation & Discoloration: Use a stainless steel brush for aluminum or a scotch-brite pad for stainless steel.

• Inspect for Cracks or Porosity: A strong TIG weld should be smooth and uniform with no visible defects.

• Use a Dye Penetrant Test (for critical welds): Helps detect micro-cracks.

Pro Tip: Stainless steel welds can be cleaned with an electrochemical weld cleaner to remove heat tint.

Common TIG Welding Mistakes & How to Avoid Them

Even experienced welders can run into issues. Here are the most common TIG welding mistakes and how to fix them.

1. Tungsten Contamination

Issue: The tungsten electrode touches the puddle, causing contamination.

Solution: Regrind the tungsten to a sharp point and avoid dipping it into the weld pool.

2. Inconsistent Arc Length

Issue: Holding the torch too close or too far from the workpiece leads to an unstable arc.

Solution: Maintain a consistent 1/8-inch arc length for the best control.

3. Overheating or Warping

Issue: Excessive heat distorts the metal, especially thin materials.

Solution: Use pulse welding, a backing plate, or clamp the workpiece to a heat sink.

4. Porosity & Gas Contamination

Issue: Small holes (porosity) appear in the weld due to poor shielding gas coverage.

Solution:

• Ensure the gas flow rate is correct (10–20 CFH for argon).

• Check for drafts or air movement disrupting the shielding gas.

• Use a gas lens to improve coverage.

5. Lack of Fusion

Issue: The weld sits on the surface but does not penetrate properly.

Solution:

• Increase amperage for better penetration.

• Slow down slightly to allow more heat buildup.

4. TIG Welding Applications: Where It’s Used

TIG welding is the go-to method for industries that demand precision, strength, and clean welds.

Automotive & Motorsports

• Used for exhausts, roll cages, and aluminum panels.

• Ensures lightweight, high-strength welds with a clean finish.

Aerospace & Aviation

• Essential for aircraft components, fuel lines, and structural welding.

• Ideal for titanium and aluminum due to their high strength-to-weight ratio.

Industrial Fabrication

• Used in pressure vessels, pipelines, and food-grade stainless steel welding.

• TIG welding’s clean, precision welds meet strict industry standards.

Art & Jewelry

• Perfect for sculptures, fine metalwork, and jewelry fabrication.

• Allows for detailed, high-quality welds with minimal heat distortion.

Medical & Pharmaceutical

• Used for surgical tools, implants, and hygienic stainless steel piping.

• Ensures contaminant-free, ultra-clean welds.

Where precision and quality matter, TIG welding delivers.

5. TIG Welding for Different Metals

Each metal requires specific techniques for best results.

Aluminum TIG Welding

• Uses AC welding to remove oxidation.

• Pure argon shielding gas ensures clean welds.

• Pre-clean with a stainless steel brush and acetone.

Stainless Steel TIG Welding

• Back purging with argon prevents oxidation.

• Short arc lengths and pulsed settings reduce heat distortion.

• Use 308L filler for 304 SS, 316L for marine applications.

Titanium TIG Welding

• Requires full argon shielding to prevent contamination.

• Use gas trailing shields for complete coverage.

• Keep tools and materials completely clean.

Copper, Brass, & Nickel Alloys

• Copper and brass need high amperage due to heat dissipation.

• Helium shielding gas improves penetration.

• Use Silicon Bronze or ERCu filler for copper welding.

Master different metals with the right setup, shielding gas, and CK Worldwide’s top-tier equipment.

6. Advanced TIG Welding Techniques

Once you’ve mastered the basics, these techniques take your TIG welding to the next level.

Pulsed TIG Welding

• Controls heat input, reducing warping and improving bead control.

• Ideal for thin metals and high-precision work.

Walking the Cup

• Used with large-diameter ceramic cups and pipe welds for a steady, consistent arc. Often with a slight oscillation pattern to control bead width.

• The ceramic cup is rocked along the workpiece for smooth movement.

Back Purging

• Essential for stainless steel and titanium to prevent oxidation.

• Uses argon to protect the back side of the weld.

• Essential for root passes or welds where the backside is exposed to atmosphere, especially in stainless and titanium.

Multi-Pass Welding

• Needed for thicker materials to prevent lack of fusion.

• First pass = penetration, subsequent passes = reinforcement.

Mastering these techniques improves weld quality, consistency, and efficiency.

7. TIG Welding Safety & Best Practices

Safety should always be a top priority when TIG welding. While it’s a precise and controlled process, it still involves high heat, intense light, and potentially hazardous fumes. Taking the right precautions helps prevent injuries and creates a safer work environment.

Personal Protective Equipment (PPE)

Wearing proper protective gear reduces the risk of burns, eye damage, and exposure to harmful radiation.

• An auto-darkening welding helmet (shade 8–13) shields your eyes from arc flash and reduces eye strain.

• Flame-resistant gloves and clothing protect your hands and body from heat and sparks.

• Safety glasses provide additional protection from debris and UV exposure.

• Leather boots or other flame-resistant footwear help prevent foot injuries.

Proper Ventilation & Fume Extraction

Even though TIG welding produces fewer fumes than other methods, certain metals release hazardous particles that can be harmful if inhaled.

• Work in a well-ventilated area to reduce exposure to harmful fumes.

• Use a fume extraction system when welding stainless steel, titanium, or other metals that produce toxic vapors.

• Wear a respirator if working in confined spaces or with materials that release dangerous fumes.

Handling & Storing Shielding Gases

Shielding gases are essential for TIG welding, but improper handling can create safety risks.

• Store gas cylinders upright and secure them properly to prevent tipping.

• Inspect hoses and regulators for leaks before each use.

• Keep cylinders capped when not in use to prevent contamination or damage.

• Avoid storing cylinders near heat sources to prevent pressure buildup or explosions.

Fire Prevention & Workspace Setup

Even though TIG welding produces minimal spatter, fire hazards still exist in the workspace.

• Keep flammable materials like rags, paper, and chemicals away from the welding area.

• Work on a fire-resistant surface, such as a metal workbench, to reduce fire risk.

• Have a fire extinguisher nearby in case of emergency.

By following these essential safety practices, you can focus on producing high-quality welds while keeping yourself and your workspace protected.

8. Troubleshooting Common TIG Welding Issues

Even with the right setup and technique, TIG welding can sometimes present challenges. Understanding common problems and how to fix them will help you produce cleaner, stronger welds.

Porosity in Welds

Porosity appears as small holes or voids in the weld, weakening its integrity.

• Causes: Contaminated shielding gas, improper gas flow, or a dirty workpiece.

• Solutions: Check for gas leaks, ensure proper gas flow (typically 15–20 CFH for argon), clean base metal thoroughly, and use high-quality filler rods.

Arc Wander

Arc wander occurs when the arc strays from the intended weld path, making it difficult to maintain control.

• Causes: Incorrect electrode grind angle, poor gas coverage, or excessive torch movement.

• Solutions: Grind tungsten to a sharp point for better arc stability, hold a steady torch angle, and ensure adequate gas shielding.

Cracking in Welds

Cracks in a weld reduce its strength and durability, leading to potential failures.

• Causes: Incorrect filler metal, excessive heat input, or rapid cooling.

• Solutions: Use the correct filler rod for the metal being welded, control heat input with proper amperage settings, and allow gradual cooling to prevent thermal stress.

By recognizing these common TIG welding issues and applying the right solutions, you can improve your weld quality and achieve better results.

9. Must-Have TIG Welding Accessories

Having the right accessories can enhance your TIG welding experience, improving precision, efficiency, and overall weld quality. Here are some essential tools every TIG welder should have.

Gas Lenses and Cups

Proper gas coverage is crucial for clean, contamination-free welds.

• Gas lenses help distribute shielding gas evenly, reducing turbulence.

• Larger cups improve gas coverage, especially for stainless steel and titanium.

Foot Pedals and Fingertip Controls

Precise heat control is essential for high-quality TIG welds.

• Foot pedals allow hands-free amperage adjustments for better weld consistency.

• Fingertip controls are ideal for mobile and overhead welding applications.

Tungsten Grinders

Properly ground tungsten ensures a stable arc and clean welds.

• A dedicated tungsten grinder creates a consistent tip shape, reducing arc wander.

• Using a grinder prevents contamination from standard grinding wheels.

Water Coolers

For high-amperage applications, keeping your torch cool extends its lifespan and improves comfort.

• Water-cooled systems help prevent overheating in long welding sessions.

• CK Worldwide’s water-cooled torches offer superior heat management and performance.

Investing in high-quality accessories ensures better results, prolongs equipment life, and enhances overall welding efficiency.

CK Worldwide: Setting the Standard in TIG Welding

TIG welding is all about precision, control, and craftsmanship. Whether you're working with aluminum, stainless steel, or exotic metals, mastering this technique requires the right knowledge, skills, and equipment. By understanding the fundamentals, investing in quality tools, and continuously refining your technique, you can achieve flawless, high-quality welds that stand the test of time.

At CK Worldwide, we’re committed to providing the industry’s best TIG welding solutions. From our cutting-edge torches to advanced welding machines and essential accessories, every product is designed to enhance performance and reliability. Whether you're a professional welder or just starting out, CK Worldwide has everything you need to take your TIG welding to the next level.

Explore our full range of TIG welding equipment and accessories atCK Worldwide’s website and weld with confidence.