tig welding guide

TIG welding — also known as Gas Tungsten Arc Welding (GTAW) — is one of the cleanest, most precise forms of welding. Using a non-consumable tungsten electrode and an inert shielding gas (usually argon), TIG allows welders to join everything from stainless steel to aluminium with exceptional accuracy.

This guide explains how TIG welding works, why it’s used, how it compares to MIG, what equipment you’ll need, and the pros and cons of the process.

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What is TIG Welding?

  • Uses a tungsten electrode that does not melt into the weld.
  • Can weld with or without filler rod.
  • Relies on argon or argon-helium gas to protect the weld from contamination.
  • Produces clean, strong, visually appealing welds without slag or spatter.

✅ Best for thin materials, exotic alloys, and high-quality visible welds.


How Does TIG Welding Work?

  1. An electrical arc forms between the tungsten electrode and the base metal.
  2. The heat melts the base metal, creating a weld pool.
  3. If needed, a filler rod is dipped into the pool while shielding gas protects the area.
  4. A foot pedal or fingertip control adjusts amperage in real time.

⚡ The tungsten electrode never touches the workpiece. Contamination = bad weld.

ComponentFunction
Tungsten ElectrodeCreates the arc (non-consumable)
Shielding Gas (Argon/He)Protects molten metal from air
Filler RodOptional; adds strength/material
Torch & Power SourceProvides heat and arc control

Why Choose TIG Welding?

  • Precision: Fine control of heat and filler, ideal for thin materials.
  • Versatility: Welds aluminium, stainless steel, nickel, copper, titanium, and more.
  • Quality: Produces clean, defect-free welds with great aesthetics.
  • Control: Foot pedal allows amperage adjustments on the fly.
  • Flexibility: Works in all positions.

💡 TIG is especially valued in aerospace, motorsport, food/medical, and art/fabrication.


TIG vs MIG Welding

FeatureTIG Welding (GTAW)MIG Welding (GMAW)
ElectrodeNon-consumable tungstenConsumable wire electrode
Filler AdditionManual (separate rod)Automatic (wire feed)
Weld QualityVery high, no spatterGood, but more spatter
Learning CurveSteeper (more skill required)Easier for beginners
SpeedSlowerFaster
Best ForThin/exotic metals, visible weldsGeneral fabrication, production speed

👉 In short: MIG is faster, TIG is cleaner.


Essential TIG Welding Equipment

EquipmentPurpose
TIG Welder (AC/DC Inverter)Powers the arc; AC for aluminium, DC for steels
Tungsten Electrodes2% Thoriated, Lanthanated, or Ceriated for DC; Pure or Zirconiated for AC
Filler RodsMatch base material (steel, stainless, aluminium, etc.)
Shielding Gas (Argon/Helium mix)Protects weld pool
Foot Pedal or Torch ControlAdjusts amperage while welding
Protective GearHelmet, gloves, PPE — essential for UV & fume protection

TIG Tungsten Electrode Guide

Tungsten electrodes come in different types, identified by color coding, each with its own properties. Choosing the right one is critical for arc stability, ease of starting, and weld quality.

Electrode TypeColor CodeCurrent TypeBest UsesNotes
Pure Tungsten (W)GreenAC onlyAluminium, magnesiumForms a clean balled tip. Least durable. Rarely used with modern inverters.
2% Thoriated (WT20)RedDCCarbon steel, stainless, nickel alloysEasy start, stable arc, durable. Slightly radioactive — handle with care.
2% Ceriated (WC20)GreyDC (low amps)Thin stainless, carbon steel, orbital weldingExcellent arc starting at low amps. Good for precision, thin materials.
2% Lanthanated (WL20)BlueAC & DCAluminium, stainless, carbon steel, copperMost versatile. Strong starts, long life. A common all-rounder.
1.5% Lanthanated (WL15)GoldAC & DCSimilar to blue electrodes, but slightly easier arc startsGood choice for hobbyists and pros alike.
Zirconiated (WZr)WhiteACAluminium and magnesiumResists contamination, maintains a balled tip. Excellent for high-amp AC.
Rare Earth / Multi-MixPurpleAC & DCWide range of materials, general purposeBlend of oxides. Very versatile, long-lasting. Often preferred with inverter TIG machines.

💡 Quick Tips:

  • For steel/stainless → Red (Thoriated), Blue (Lanthanated), or Grey (Ceriated).
  • For aluminium → Green (Pure) on older transformer sets, but Blue (Lanthanated) or Purple (Rare Earth) is best for inverters.
  • Always grind tungsten lengthwise (not sideways) for arc stability.
  • Keep a dedicated tungsten for each material type to avoid contamination.

Tungsten DiameterAC Amperage RangeDC Amperage RangeTypical Material ThicknessNotes
1.0 mm (0.040″)10–60 A10–75 AUp to ~1 mm sheet metalIdeal for very thin stainless/aluminium, low-amp precision work.
1.6 mm (1/16″)20–90 A15–150 A1–3 mmMost versatile size for light fabrication and thin to medium sections.
2.4 mm (3/32″)60–150 A70–200 A3–6 mmCommon choice for general TIG work, balances control and penetration.
3.2 mm (1/8″)100–200 A150–300 A6–10 mmFor thicker plate and higher amperage welding.
4.0 mm (5/32″)200–300 A250–400 A10 mm+Heavy-duty applications; requires high-power TIG machines.

💡 Rules of Thumb:

  • Steel & stainless: 1.6 mm or 2.4 mm tungstens cover 80% of jobs.
  • Aluminium: Use slightly larger tungsten sizes than for DC steel (because AC requires more current).
  • Too small tungsten = overheating, tip erosion.
  • Too large tungsten = harder arc starts, less stable arc at low amps.

Advantages & Disadvantages of TIG Welding

Pros:

  • Highest weld quality and appearance
  • Welds almost all metals, including very thin stock
  • No flux, slag, or spatter
  • Filler optional — autogenous welds possible
  • Welds in all positions

Cons:

  • Slower than MIG or Stick
  • Requires high skill level (steeper learning curve)
  • Sensitive to shielding gas issues (wind makes outdoor TIG difficult)
  • Equipment is more expensive

Summary

TIG welding is the gold standard for precision welding. It produces clean, strong, and aesthetically perfect welds across a wide range of metals — though at the cost of speed, ease of use, and equipment price.

  • Use TIG for quality and detail (aerospace, stainless, aluminium).
  • Use MIG for speed and productivity (general fabrication).

👉 Get started today with the right consumables: