Tips for Setting Up Your TIG Welder for Different Metals

TIG welding different metals effectively requires an understanding of each metal’s unique properties and challenges. Whether you’re working with aluminum, steel, stainless, copper, or titanium, adjusting your setup accordingly can make a big difference in weld quality. Having a versatile welder, like the MT200 ACDC or MT375 ACDC from CK Worldwide, can make this process easier by giving you precise control over settings like AC balance, pulse, and amperage—key elements for working with different materials. Here’s a guide to fine-tuning your setup for each metal.

1. Aluminum: Balancing Cleaning and Heat Control

Aluminum is notorious for its oxide layer, which melts at a much higher temperature than the base metal. The key to successful aluminum welding lies in managing this oxide layer and controlling heat.

Polarity & AC Balance: Use AC mode for aluminum, as it alternates between breaking up the oxide layer and fusing the metal. Adjustable AC balance, like what you’ll find on both the MT200 and MT375, lets you increase cleaning action without overheating the base material.
Amperage Control: Aluminum requires careful amperage management, especially on thinner sections. The MT200 ACDC is excellent for thinner materials, while the MT375 ACDC handles thicker aluminum sections with ease, providing extra power for deeper penetration.
Shielding Gas: Pure argon is ideal for most aluminum applications, but thicker materials can benefit from an argon-helium mix for better penetration.

2. Steel: Consistent Heat and Arc Control

Steel is more forgiving than aluminum but still requires consistent heat and stable arc control to produce a clean, strong weld.

Polarity: DCEN (Direct Current Electrode Negative) is recommended for steel, allowing for deep penetration and a stable arc.
Amperage: Steel can handle higher amperage, so adjust accordingly based on thickness. Both the MT200 and MT375 make fine-tuning amperage easy, giving you precise control to create smooth, stable puddles.
Filler Rod: Use ER70S-2 for mild steel and ER308L for stainless applications.
Shielding Gas: 100% argon works well, providing stable arc characteristics and reducing contamination.

3. Stainless Steel: Managing Heat and Avoiding Discoloration

Stainless steel can warp and discolor easily if overheated. This requires careful control over heat input and sometimes even additional cooling.

Polarity: Like mild steel, DCEN is preferred for stainless.
Pulse Feature: Pulse settings can be useful in reducing heat buildup. Both the MT200 and MT375 have pulse features, which let the weld cool between pulses, reducing warping and maintaining the stainless finish.
Shielding Gas: Pure argon is ideal, but for thicker sections, a slight helium addition can improve penetration.

4. Copper: Managing High Conductivity and Penetration

Copper’s high thermal conductivity draws heat away quickly, making it challenging to maintain penetration, especially on thicker pieces.

Polarity: DCEN keeps the heat focused on the base metal.
Amperage: Copper needs high amperage to penetrate well, especially in thicker sections. The MT375 is ideal for heavier copper projects, with its power range providing the necessary amperage for consistent results.
Shielding Gas: Argon-helium mixtures work well for copper, with the helium providing a hotter arc for better penetration.

5. Titanium: Protect Against Contamination and Overheating

Titanium is highly sensitive to air contamination and overheating, requiring meticulous shielding and controlled heat input.

Polarity: DCEN is essential for titanium to avoid overheating the tungsten.
Amperage: Set amperage based on material thickness, but be cautious with overheating. The MT200 works well for thin titanium projects, while the MT375 is suited for thicker applications needing extra power.
Shielding Gas: Use pure argon and consider adding a trailing shield for extra protection. Titanium needs to stay isolated from air exposure to maintain its weld integrity.

Final Thoughts

Tailoring your TIG setup for different metals can elevate the quality and consistency of your welds. The MT200 ACDC and MT375 ACDC from CK Worldwide offer flexibility with AC/DC capabilities, adjustable AC balance, pulse settings, and a wide amperage range, giving you the precision needed to tackle aluminum, steel, stainless, copper, and titanium. The MT200 is compact and ideal for lighter work, while the MT375 has the power to handle larger, thicker projects. With these tools, you’re set up for success on a wide range of metals and projects, no matter the complexity.