TIG Welding
TIG welding is a precise and versatile process used to create clean, high-quality welds on a variety of metals. We have years of experience applying this method to achieve strong, visually consistent results. It uses a nonconsumable tungsten electrode, shielding gas, and accurate heat control for exceptional precision.
This guide explains what TIG welding is, how it works, and the tools and steps involved. We also cover its main benefits and the key drawbacks to consider.
What this article covers:
What Is TIG Welding?
TIG welding is gas tungsten arc welding, or GTAW. It uses a nonconsumable tungsten electrode to generate an arc and melt the base metals.
An inert gas, usually argon, shields the weld area to keep it pristine. It's favored for stainless steel, aluminum, copper alloys, and other metals that need a clean, strong joint. Unlike MIG welding, which feeds a consumable wire automatically, TIG gives you full control over filler application for maximum precision.
How Does TIG Welding Work?
At its core, TIG welding works by forming an arc using a tungsten electrode, which does not melt. The arc heats the base metal and, optionally, a filler rod you feed by hand. The inert shielding gas, such as argon or helium, protects the weld puddle from air contamination.
It's precise, clean, and controllable. Your foot pedal or fingertip control lets you modulate heat as you weld, allowing more finesse than processes like flux core welding that are designed for speed and portability.
Tools & Supplies for TIG Welding
Having the right gear makes TIG welding smoother, safer, and more precise. From the torch in your hand to the gas in your tank, every piece of equipment has a specific job. Here's what each tool or supply does and why it matters:
TIG Welding Torch and Tungsten Electrode
The TIG welder is the most important part of the setup. It directs the arc to your workpiece and houses the tungsten electrode.
The tungsten creates the arc without melting, though it gradually wears and needs occasional regrinding or replacement.
We've found ceriated and lanthanated electrodes offer the best arc stability for most projects, providing a smooth start and steady performance whether you're working on steel or aluminum.
Shielding Gas Supply
The shielding gas protects the molten weld pool from oxygen, nitrogen, and other contaminants in the air. Pure argon is the most common choice because it provides consistent coverage and is versatile across many metals.
For thicker materials or when more heat is needed, an argon-helium mix can help achieve deeper penetration and faster travel speeds. The right gas flow rate is just as important as the gas itself, as too much or too little can compromise weld quality.
PPE and Ground Clamp
Personal protective equipment keeps you safe from intense heat, UV light, fumes, and flying sparks. A welding helmet with the correct shade lens, heavy-duty welding gloves, and flame-resistant clothing are non-negotiable.
The ground clamp completes the electrical circuit between your machine and the workpiece. Without a secure, clean connection, your arc will be unstable, and you may damage your equipment or produce poor weld quality.
Power Source with Control (Foot Pedal or Torch Control)
A DC or AC/DC welding machine gives you the arc power. Foot pedals or torch-mounted controls let us fine-tune the heat. We always recommend HF start capability, so you don't have to scratch the tungsten against your workpiece.
Filler Rod (Optional, Depending on Welding Type)
The filler rod adds extra material to the joint, ensuring strength and, in some cases, building up the weld profile. You feed it into the weld pool by hand while maintaining control of the torch in your other hand.
Some TIG welds, called autogenous welds, don't require filler, but most structural applications benefit from it. Choosing the right filler material to match your base metal is critical for achieving a strong, defect-free weld.
TIG Welding Process
A good TIG weld starts with a solid process. Each step builds on the one before it, and skipping or rushing any part can compromise the final result. Here's how to do it right from start to finish:
Step 1: Setup
Begin by selecting the correct tungsten type and size for the material you are welding. Install it securely in the torch, making sure the tip is ground to the right angle for the job. Attach the ground clamp to a clean, bare metal surface near the weld zone to ensure a stable circuit.
Set your machine to AC or DC depending on the material, and adjust amperage for the thickness of the workpiece. Open the shielding gas cylinder, set the regulator to the recommended flow rate, and double-check all connections before striking an arc.
A proper setup prevents problems later and sets you up for consistent, clean welds.
Step 2: Prepare the Workpiece
Thorough surface preparation is essential for strong welds. Use a dedicated stainless steel wire brush or grinder to remove rust, paint, scale, or oxidation.
For aluminum, an acetone wipe can remove oils and residue that would otherwise contaminate the weld. Keep in mind that even fingerprints can cause porosity in sensitive materials. We've seen weld quality improve dramatically when extra time is spent cleaning before welding.
Step 3: Strike the Arc
Use a high-frequency start if your machine has it, as it initiates the arc without contact between the tungsten and the metal. This keeps the tungsten clean and reduces the risk of contamination in the weld.
For machines without an HF start, use a scratch start by lightly dragging the tungsten tip across the surface before pulling back to create the arc.
Keep your hand steady and your torch angle consistent as you start, since movement at this stage can make it harder to control the puddle once it forms. Although the techniques differ, one of the ways in which this is similar to stick welds is the need for a stable start.
Step 4: Control the Heat
Regulating heat is one of the most critical parts of TIG welding. Use your foot pedal or torch-mounted control to adjust amperage in real time as you move along the joint. Too much heat can cause burn-through, distortion, or an overly wide bead, while too little can result in incomplete fusion.
Keep the puddle just large enough to fuse the base metals without excessive melting. Watching the edges of the puddle closely will help you know when to add filler or reduce the heat.
Step 5: Add Filler (If Needed)
Hold the filler rod at a shallow angle and feed it smoothly into the leading edge of the puddle. Dipping too aggressively or touching the tungsten can contaminate the weld and ruin the electrode tip. Choose a filler metal that matches or complements your base metal for strength and compatibility.
Keep your motions consistent, adding filler at the same point in the puddle for an even bead profile. With practice, this step becomes second nature and helps produce strong, uniform welds.
Step 6: End and Shield
When you reach the end of the weld, ease off the foot pedal slowly to reduce heat without creating a crater. Keep the torch in place for a few seconds to allow the shielding gas to cover the cooling weld pool.
This post-flow period prevents oxidation and keeps the finished weld bright and clean. Depending on your machine settings and the material, post-flow can last anywhere from 5 to 15 seconds.
Skipping this step can leave the weld surface dull, brittle, or prone to cracking. Maintaining coverage here is just as important as it is in any process involving a welding arc.
Benefits of TIG Welding
TIG welding offers a level of control and finish that other processes struggle to match. These are the key advantages we've seen time and again:
Exceptional Cleanliness and Precision
TIG welds are smooth, well-defined, and free of spatter or slag. The inert shielding gas keeps contamination low, resulting in a clean bead that often needs little post-weld cleanup. This makes TIG ideal for projects where both strength and appearance matter.
Versatility Across Metals
TIG works with stainless steel, carbon steel, aluminum, copper, brass, and even titanium. With the right tungsten, filler, and settings, it can handle everything from custom fabrication to precision repairs without switching processes.
Heat Control
Foot pedals or torch controls allow you to adjust heat instantly during the weld. This is especially important for thin materials or parts with varying thickness, where consistent penetration and bead shape are critical.
All Position Welding
TIG can be done flat, horizontal, vertical, or overhead with strong, consistent results. This flexibility is valuable when the workpiece can't be moved into a perfect position.
Conclusion
TIG welding is a precise, versatile process capable of producing clean, strong welds across a wide range of metals. It requires the right tools, a well-prepared workpiece, and careful control over heat and filler application to achieve consistent results.
While the learning curve is steeper and the process slower than other methods, the benefits in quality, appearance, and flexibility make it an essential skill for many welding applications. With the proper setup and practice, TIG welding can meet both structural and aesthetic demands.
For reliable, high-quality equipment to support your TIG welding projects, choose from our proven selection at Badass Welding Products.