TIG welding (GTAW) is known for producing precise, high-quality welds — but it is also one of the most demanding welding processes. Small mistakes in heat control, gas shielding, or technique can lead to visible defects or hidden weaknesses that compromise weld quality.
This guide breaks down the most common TIG welding problems, what causes them, and how to prevent or fix them. Alongside detailed reference tables, we’ve included best-practice advice for tungsten preparation, shielding gas troubleshooting, and electrode care.
👉 Browse our full range of TIG Welding Supplies — from rods and tungstens to torches and gas accessories.
Navigating Common TIG Welding Problems
Even the most skilled welders face defects from time to time. The table below is your quick reference guide to the main TIG welding quality issues — with causes, prevention strategies, detection methods, and risk levels.
In this guide:
TIG Welding Defects Reference Table
Defect | Description | Causes | Prevention | Detection | Risk Level |
---|---|---|---|---|---|
Porosity | Tiny holes or bubbles weaken the weld | Contamination, moisture, poor gas coverage | Clean base/filler metal, dry storage, correct shielding gas flow | Visual inspection, NDT (ultrasonic, radiography) | Medium (structural + cosmetic) |
Cracking | Fractures in or near the weld | Rapid cooling, wrong filler, poor prep | Preheat where needed, match filler, control cooling | Visual, dye penetrant | High (structural failure) |
Crater Formation | Pit at weld end | Arc cut too quickly, no filler backfill | Ramp down current, add filler at end, backfill crater | Visual inspection | Medium |
Incomplete Fusion | Weld metal not bonded to base | Wrong angle, low heat, poor filler use | Correct torch angle, adjust amperage, apply filler properly | Visual, ultrasonic | High |
Tungsten Inclusions | Tungsten trapped in weld | Dipping tungsten, damaged electrode | Maintain steady arc length, replace bad electrodes | Visual spots, NDT | Medium |
Distortion | Workpiece warps or bends | Too much heat, uneven welding, poor clamping | Minimise heat input, balance welds, secure clamping | Visual, precision measuring | Medium |
Lack of Penetration | Weld too shallow, weak joint | Low amps, fast travel, poor angle | Increase amperage, adjust angle, reduce travel speed | Cross-section, ultrasonic | High |
Oxidation / Discolouration | Weld turns blue/black, loss of corrosion resistance | Poor gas shielding, contamination, excess heat | Correct gas flow & coverage, clean base metal, lower heat | Visual colour check | Medium–High |
Electrode Deterioration | Tungsten wears, contaminates arc | Wrong tungsten/current, bad grinding, poor storage | Match tungsten to process, grind correctly, store properly | Visual electrode check, arc instability | Low–Medium |
Porosity in TIG Welding: Bubbles and Holes in the Weld
Porosity is one of the most common TIG welding defects — and one of the most frustrating. It appears as tiny bubbles or pinholes in the weld bead or just beneath the surface. While it may seem like a cosmetic issue, porosity reduces strength, toughness, and corrosion resistance, making it a serious quality concern.
What Causes Porosity?
Porosity is almost always the result of gas entrapment — contamination or poor shielding causes gases (hydrogen, oxygen, nitrogen) to get trapped in the weld pool. The most common culprits include:
- Contaminated base material → oil, paint, grease, rust, or mill scale introducing gas.
- Contaminated filler rod → dirty TIG rods, stored in damp conditions.
- Moisture → from the atmosphere, storage areas, or handling with bare hands.
- Shielding gas issues → wrong flow rate, turbulence, leaks, or draughts disrupting coverage.
- Improper torch technique → holding too long an arc, erratic movement, or torch angle exposing the pool.
How to Prevent Porosity
A clean weld environment and consistent shielding are the key defenses.
✅ Clean everything → grind, wire brush, or solvent-clean the joint area and filler rod.
✅ Dry storage → keep TIG filler rods in sealed tubes or electrode quivers/ovens to avoid moisture pickup.
✅ Check gas flow → typical argon flow is 10–20 L/min (20–40 CFH) depending on cup size and joint type. Too high = turbulence, too low = air ingress.
✅ Shield from draughts → even light air currents can disrupt argon coverage.
✅ Maintain technique → correct arc length (2–3 mm), stable angle (~15° torch tilt), and consistent travel speed.
✅ Use quality filler rods → match material grade and diameter to avoid contamination or mismatch.
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Detecting Porosity
- Visual inspection → surface pinholes, pores, or rough texture.
- Bend/etch tests → reveal subsurface porosity.
- NDT (ultrasonic/radiographic testing) → detects porosity hidden inside critical welds.
⚠️ Pro tip: If porosity keeps appearing despite good prep, check your shielding gas purity and regulator system. Contaminated argon or leaking hoses can undo even perfect welding technique.
👉 For consistent shielding, see our Gas Regulators & Flow Control Solutions.
Cracking in TIG Welding: Preventing Fractures
Cracking is one of the most serious TIG welding defects because it directly threatens the strength and safety of the joint. Unlike porosity, which is often localised, cracks can propagate under stress and lead to catastrophic failure.
Cracks may form during welding (hot cracks) or after solidification (cold cracks), and they can appear in the weld metal, heat-affected zone (HAZ), or even along the fusion line.
Common Causes of Cracking
Understanding what drives cracking is the first step to eliminating it:
- Rapid cooling → thick materials or highly restrained joints cool too quickly, locking in stress.
- Wrong filler metal → mismatch in composition or ductility creates brittle welds.
- Hydrogen absorption → moisture from rods or the environment leads to hydrogen-induced cracking.
- Joint design → poor fit-up, sharp corners, or excessive restraint concentrate stresses.
- Improper preheat/interpass temperature → especially critical in high-strength steels, tool steels, or dissimilar welds.
Prevention Strategies
✅ Preheat thick or hardenable steels → slows cooling and reduces residual stress.
✅ Match filler material correctly → always use rods compatible with the base metal grade. (See our TIG Rod Selector Tool to get it right first time.)
✅ Control interpass temperature → maintain consistent heat to prevent brittle microstructures.
✅ Good joint design → aim for smooth transitions, correct bevel angles, and proper gap.
✅ Avoid contamination → keep filler rods dry and clean, ideally stored in electrode ovens or quivers.
✅ Use higher duty-cycle TIG welders → machines with stable output help avoid erratic heat input.
👉 Browse our TIG Welding Machines — designed for precision and stable arc performance to help prevent cracking in critical applications.
Detecting Cracks
- Visual inspection → surface cracks may appear as fine dark lines.
- Dye penetrant testing → highlights even hairline surface cracks.
- Ultrasonic or radiographic testing → essential for structural and pressure-critical welds.
⚠️ Pro tip: Stainless steels and nickel alloys are especially prone to hot cracking — ensure you use the correct filler grade and control cooling rates.
👉 For best results, pair quality tungsten electrodes with a dedicated tungsten grinder to ensure a stable arc and minimise crack-inducing defects.
Crater Formation in TIG Welding: Addressing and Preventing Welding Pits
Crater formation is a common TIG welding defect where a small pit or depression forms at the end of a weld. While it may seem cosmetic, craters often become the starting point for crater cracks, which can severely weaken the joint under stress. For high-spec work — from pressure vessels to aerospace — crater prevention is a must.
Common Causes of Crater Formation
- Abrupt arc termination → shutting off the current too quickly leaves a molten pool that contracts and sinks.
- Insufficient filler at weld end → not “topping off” the weld puddle leaves a hollow.
- Lack of backfilling technique → failing to briefly move back into the weld to fill the crater.
- Improper slope-down settings → machines without adjustable current downslope can cause abrupt stops.
Prevention Strategies
✅ Use downslope / crater fill settings → modern TIG welding machines often include adjustable downslope or crater fill functions to taper off current smoothly.
✅ Backfill technique → as you finish the weld, move slightly back over the crater and add a dab of filler rod to fill the depression.
✅ Control filler addition → ensure sufficient filler is used at the end, particularly on aluminium and stainless steels prone to crater cracks.
✅ Keep heat steady → avoid a sudden torch lift or filler withdrawal at the weld’s end.
Detecting Crater Defects
- Visual inspection → craters appear as a visible pit or “dimple” at the weld end.
- Magnified inspection → small crater cracks can be spotted under magnification.
- NDT methods → dye penetrant testing is effective for detecting crater cracks in stainless and nickel alloys.
⚠️ Pro tip: Aluminium is especially prone to crater cracks due to its high thermal conductivity and shrinkage — always use downslope and filler backfill when TIG welding aluminium.
👉 Ensure consistent quality by pairing quality TIG filler rods with your process. Our range covers stainless, aluminium, nickel alloys, and more — all precision-matched to minimise crater-related defects.
Incomplete Fusion in TIG Welding: Ensuring Strong Bonds
Incomplete fusion occurs when the weld metal fails to fully bond with the base material or previous weld passes. It creates weak points that can lead to cracking, lack of strength, and weld failure under load. Because TIG welding is often chosen for high-integrity work (aerospace, stainless pipework, precision fabrication), avoiding incomplete fusion is absolutely critical.
Common Causes of Incomplete Fusion
- Incorrect torch angle → the arc fails to reach the joint root or sidewalls.
- Insufficient heat input → the base metal doesn’t melt adequately, leaving a cold joint.
- Too fast travel speed → weld pool solidifies before bonding properly.
- Improper filler rod use → filler added in the wrong place can sit on top of the joint without bonding.
- Contaminated surfaces → oxides, oil, or mill scale block fusion.
Prevention Strategies
✅ Adjust torch angle → keep the tungsten angled 10–15° from vertical, pointing into the weld pool.
✅ Use correct amperage → follow the “1 amp per 0.001” thickness rule and ensure penetration without excessive heat input.
✅ Control travel speed → move steadily to allow time for fusion, especially on thicker joints.
✅ Place filler correctly → dip filler rod at the leading edge of the weld pool, not behind it.
✅ Prepare surfaces → grind, wire-brush, or chemically clean before welding to remove oxides and contaminants.
Quick Reference: Recommended Amperage for TIG Fusion
Material Thickness | Suggested Amperage (DCEN, Argon Shielding) | Notes |
---|---|---|
1 mm (0.040″) | 30–50 A | Thin sheet → requires tight arc and low heat input |
2 mm (0.080″) | 50–80 A | Common for stainless sheet |
3 mm (1/8″) | 80–120 A | Add filler rod steadily to maintain fusion |
6 mm (1/4″) | 130–180 A | May require preheat or multiple passes |
10 mm (3/8″)+ | 200–250 A+ | Multi-pass, bevel prep essential |
⚠️ Always check your Welding Procedure Specification (WPS) if working on critical joints — it overrides general guidance.
Detecting Incomplete Fusion
- Visual inspection → weld bead may look undercut or show lack of tie-in at the edges.
- Bend tests → common in training; poor fusion will crack along the weld line.
- Ultrasonic testing (UT) → industry-standard for detecting hidden lack of fusion in structural work.
- X-ray (RT) → used in critical industries like aerospace and nuclear fabrication.
⚡ Pro Tip: A sharp, well-prepared tungsten electrode makes a big difference in arc focus and penetration. Keep yours consistent with a dedicated tungsten grinder to avoid fusion problems caused by poor arc stability.
👉 Browse our full range of TIG welding supplies — including filler rods, tungsten electrodes, and consumables — to ensure reliable fusion on every weld.
Tungsten Inclusions in TIG Welding: Keeping Your Welds Clean
Tungsten inclusions occur when small pieces of the tungsten electrode break off and become trapped in the weld metal. This creates weak points, reduces ductility, and introduces defects that can cause failure under stress. Since TIG welding relies on a non-consumable electrode, preventing inclusions is vital for both weld integrity and appearance.
Common Causes of Tungsten Inclusions
- Accidentally dipping the tungsten into the weld pool → contaminates the electrode and deposits tungsten into the weld.
- Touching the filler rod against the tungsten → can cause tungsten particles to break off.
- Using a damaged or poorly ground electrode → uneven tips arc erratically and increase risk of breakage.
- Overheating the tungsten → running too high amperage for the tungsten size/alloy.
- Incorrect polarity → e.g., using DCEN tungsten with AC aluminium welding without proper prep.
Prevention Strategies
✅ Maintain correct arc length → keep tungsten 2–5 mm above the weld pool, avoiding dips.
✅ Grind electrodes correctly → grind longitudinally (not sideways) for stable arc focus; use a tungsten grinder for consistency.
✅ Select correct tungsten type & size → match alloy and diameter to current (e.g., 2.4 mm 2% lanthanated for 100–200 A DC).
✅ Use proper current settings → don’t exceed tungsten amperage ratings — overheating leads to tip erosion.
✅ Keep filler away from tungsten → feed filler at the leading edge of the puddle, not directly under the arc.
✅ Replace damaged electrodes → cracked, split, or contaminated tungsten should be discarded, not reused.
Quick Reference: Tungsten Size vs Amperage
Tungsten Diameter | Current Range (DCEN, Argon Shielding) | Notes |
---|---|---|
1.0 mm (0.040”) | 10–70 A | Thin sheet, precision TIG |
1.6 mm (1/16”) | 50–150 A | Light to medium gauge |
2.4 mm (3/32”) | 80–200 A | General purpose, most common |
3.2 mm (1/8”) | 150–300 A | Heavy plate, high current work |
💡 Tip: Always consult the electrode manufacturer’s rating for AC vs DC, as limits vary.
Detecting Tungsten Inclusions
- Visual inspection → small bright specks in the weld bead.
- X-ray / radiographic testing → shows dense tungsten particles inside the weld.
- Ultrasonic testing (UT) → picks up inclusions below the surface in structural work.
⚡ Pro Tip: Storing electrodes correctly in quivers and ovens helps prevent contamination and damage that can contribute to inclusions.
👉 Browse our full range of tungsten electrodes and TIG rods to ensure clean, defect-free welds every time.
Distortion in TIG Welding: Maintaining Shape and Accuracy
Distortion happens when the welded material warps or bends due to uneven heating and cooling. Because TIG welding produces a very concentrated arc and high heat input, distortion can be a real problem — especially on thin materials like stainless steel sheet. Even small amounts of movement can ruin dimensional accuracy, cause misalignment, or lead to rejected parts.
Common Causes of Distortion
- Excessive heat input → too high amperage or welding too slowly.
- Unbalanced welds → welding more on one side of the joint than the other.
- Improper clamping/fixturing → workpieces moving during welding.
- Long continuous welds → heat builds up and pulls metal as it contracts.
- Poor sequencing → welding out of order, creating uneven stress.
Prevention Strategies
✅ Control heat input
- Use the lowest amperage possible while still achieving full penetration.
- Use pulsed TIG settings to control arc heat and limit distortion.
✅ Backstep or skip welding
- Don’t weld everything in one go; stitch or stagger welds to spread heat.
✅ Clamp and fixture properly
- Use strong pipe stands, jigs, or pipe clamps to hold work securely.
✅ Balance welds
- Weld evenly on both sides of the joint to avoid pulling the metal out of alignment.
✅ Pre-plan weld sequence
- Start from the centre or alternate sides to distribute heat more evenly.
Quick Reference: Heat Input vs Distortion Risk
Material Thickness | Distortion Risk | Best Practice |
---|---|---|
< 2 mm sheet | Very High | Use pulsed TIG, copper backing bars, low amps |
2–6 mm plate | Medium | Stagger welds, clamp securely |
> 6 mm plate | Low | Preheat thicker sections to reduce stress |
Detecting Distortion
- Visual inspection → look for bowing, twisting, or misalignment.
- Measuring tools → use calipers, straight edges, or jigs to check flatness.
- Fit-up check → ensure parts still align properly after tack welding.
⚡ Pro Tip: Using TIG machines with pulsed welding functions helps reduce heat buildup and minimises distortion — check out our range of TIG welders designed for thin stainless, aluminium, and precision fabrication.
Lack of Penetration in TIG Welding: Achieving Full Depth
A weld that doesn’t fully penetrate the joint is one of the most serious TIG welding defects. It leaves weak spots in the weld that can’t handle stress, leading to cracking, leaks, or outright failure. Because TIG welding is often used on high-spec projects (stainless pipework, aerospace, food-grade stainless), ensuring full penetration is critical.
Common Causes of Lack of Penetration
- Insufficient heat input → amperage too low for material thickness.
- Incorrect torch angle → arc doesn’t reach the root of the joint.
- Travel speed too fast → weld pool doesn’t have time to melt through.
- Poor joint preparation → root gap too tight, bevel angle too small.
- Wrong filler rod size → too small = weak bead, too large = chilling effect.
Prevention Strategies
✅ Match amperage to thickness
- Rule of thumb: ~1 amp per 0.001” of material.
- Example: 3 mm stainless → ~120 amps.
✅ Set correct torch angle
- Aim for ~10–15° torch tilt, pointing arc into the root of the joint.
✅ Control travel speed
- Too fast = shallow weld, too slow = overheating/distortion. Aim for steady, consistent movement.
✅ Prepare the joint correctly
- Bevel thicker materials (>3 mm).
- Maintain a consistent root gap to ensure penetration.
✅ Choose correct filler rod size
- Match to base metal thickness (see table below).
Quick Reference: TIG Amperage & Rod Size by Thickness
Material Thickness | Amperage Range (DCEN) | Typical TIG Rod Diameter |
---|---|---|
1–2 mm | 40–70 A | 1.0 – 1.6 mm |
2–3 mm | 70–120 A | 1.6 – 2.4 mm |
3–5 mm | 120–180 A | 2.4 – 3.2 mm |
5–8 mm | 180–250 A | 3.2 mm + |
(Values are typical; always confirm with WPS or filler manufacturer guidelines.)
Detection of Lack of Penetration
- Visual check → shallow bead, no root reinforcement, underfill.
- Bend test → weld fails early at the joint line.
- Non-destructive testing (NDT) → ultrasonic or radiography shows incomplete root fusion.
⚡ Pro Tip: A stable arc is key to good penetration. Make sure your tungsten is ground properly with a tungsten grinder to maintain focus and arc control.
👉 Browse our full range of TIG rods to ensure you’re using the right filler for every material and thickness.
Oxidation & Discoloration in TIG Welding: Preserving Weld Purity
TIG welding is known for producing clean, visually appealing welds. But if oxidation or discoloration appears (blue, brown, black, or even flaky surfaces), it’s a clear sign of contamination. Beyond aesthetics, oxidation can compromise corrosion resistance, especially in stainless steels and titanium, where surface cleanliness is critical.
Common Causes of Oxidation & Discoloration
- Inadequate shielding gas coverage → weld pool exposed to oxygen/nitrogen.
- Contamination → dirty base metal or filler rods introduce impurities.
- Excessive heat input → overheated metal reacts with air faster.
- Poor post-flow settings → tungsten and weld pool exposed after arc stop.
- Damaged torch components → cracked gas lens, clogged collet, or worn cup.
Prevention Strategies
✅ Ensure correct shielding gas
- Use high-purity argon (99.99%) for most TIG work.
- Consider argon/helium mixes for deeper penetration on thick aluminium/stainless.
✅ Maintain proper gas flow & coverage
- Typical flow: 6–12 L/min (check torch size and cup).
- Use a gas lens for smoother laminar flow.
- Ensure torch angle doesn’t blow gas away from the weld.
✅ Keep everything clean
- Mechanically or chemically clean base metals before welding.
- Use clean TIG filler rods.
- Store rods properly in electrode ovens/quivers to prevent moisture.
✅ Control heat input
- Use pulse settings where available.
- Don’t dwell too long in one spot.
✅ Check post-flow settings
- 5–10 seconds post-flow protects both tungsten and weld pool.
- More for stainless, titanium, or nickel alloys.
Quick Reference: TIG Shielding Gas & Cup Size
Material | Typical Cup Size | Gas Flow Rate (L/min) | Notes |
---|---|---|---|
Stainless Steel | #6–#8 | 8–12 | Gas lens improves coverage |
Aluminium | #5–#7 | 8–10 | Higher flow if using helium mix |
Titanium / Exotic | #10–#12 | 12–20 | Use trailing shields for critical welds |
Thin Sheet (all) | #4–#6 | 6–8 | Lower flow prevents turbulence |
Detection of Oxidation
- Visual → rainbow colours, brown/black oxides, dull surface.
- Mechanical → brittle weld bead, poor corrosion resistance.
- Testing → pickling paste reveals hidden oxide layers on stainless.
⚡ Pro Tip: A poorly prepared tungsten tip can cause an unstable arc that overheats the weld pool, leading to discoloration. Always prep with a dedicated tungsten grinder.
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Electrode Deterioration in TIG Welding: Keeping Your Tungsten in Top Shape
The tungsten electrode is the heart of TIG welding. If it’s damaged, contaminated, or incorrectly prepared, the entire weld suffers. Electrode deterioration leads to arc instability, tungsten inclusions, and inconsistent weld quality. Keeping your tungsten sharp and clean is critical for precision work.
Common Causes of Electrode Deterioration
- Improper grinding → grooves, contamination, or blunt tips cause unstable arcs.
- Wrong electrode type → using pure tungsten on DC welding, or incorrect alloy for the base metal.
- Overheating → caused by low post-flow, incorrect current settings, or torch angle.
- Arc strikes & contamination → dipping the tungsten in the weld pool or touching filler rod.
- Poor storage → electrodes absorbing moisture, dirt, or oil.
Prevention Strategies
✅ Match tungsten type to application
- Thoriated (WT20) → excellent for DC welding (steel, stainless).
- Ceriated (WC20) / Lanthanated (WL15/WL20) → versatile, lower current starts, longer life.
- Zirconiated (WZ8) → best for AC aluminium, resists contamination.
👉 Shop our full range of TIG tungsten electrodes for every process.
✅ Grind properly
- Use a dedicated tungsten grinder (not a bench grinder shared with steel).
- Always grind lengthwise to the electrode (not across).
- Keep tip angle consistent (20–30° typical).
✅ Control heat & post-flow
- Ensure adequate gas post-flow (5–10 sec for most materials).
- Use correct amperage and polarity for electrode type.
✅ Avoid contamination
- Maintain a steady hand to prevent dipping tungsten.
- Keep filler rod tip within the shielding gas envelope.
✅ Store electrodes correctly
- Use clean containers or electrode quivers/ovens to keep them dry and contamination-free.
Quick Reference: Tungsten Selection Guide
Electrode Type | Colour Code | Best For | Polarity | Notes |
---|---|---|---|---|
2% Thoriated (WT20) | Red | Mild steel, stainless (DC) | DCEN | Long life, strong arc; slightly radioactive |
2% Ceriated (WC20) | Grey | Steel, stainless, low-amp starts | DCEN/AC | Easy starts, good for thin sheet |
1.5–2% Lanthanated (WL15/WL20) | Gold/Blue | General-purpose (AC & DC) | Both | Very versatile, longer life |
Zirconiated (WZ8) | White | Aluminium (AC) | AC | Resists contamination, ball tip on AC |
Pure Tungsten (WP) | Green | Older AC aluminium welding | AC | Rarely used now; replaced by lanthanated/zirconiated |
Detection of Electrode Wear
- Arc instability → wandering or inconsistent arc.
- Poor weld quality → porosity, inclusions, or irregular bead shape.
- Tip inspection → rounded, contaminated, or broken tips indicate deterioration.
⚡ Pro Tip: If you notice frequent tungsten inclusions or unstable arcs, it’s often quicker and cheaper to replace the electrode than to keep “making do.”
👉 Keep your welds consistent with TIG rods, tungstens, and consumables always in stock.
Final Thoughts: Mastering TIG Welding Quality
TIG welding is all about precision. From porosity and cracking to oxidation and electrode wear, every common defect has a cause — and more importantly, a solution. With clean prep, correct parameters, good shielding, and properly maintained electrodes, you can consistently produce strong, beautiful welds that meet the highest standards.
Key Takeaways
- Cleanliness is critical → keep base metal, filler rods, and tungsten free from contamination.
- Heat control matters → too much or too little can cause cracking, lack of penetration, or distortion.
- Shielding gas is your ally → correct type, flow rate, and post-flow prevent oxidation and porosity.
- Equipment condition counts → sharp tungsten, reliable regulators, and well-maintained machines make all the difference.
👉 Every defect avoided saves time, money, and rework — while ensuring safety and structural integrity.
Equip Yourself for Success
Whether you’re tackling stainless, aluminium, or exotic alloys, having the right consumables and equipment is essential.
- 🛠️ Shop TIG Welding Supplies — rods, tungstens, cups, and accessories
- 🔩 TIG Welding Rods — matched to every base metal
- ⚡ Tungsten Electrodes — thoriated, ceriated, lanthanated & more
- 🎯 Tungsten Grinders — precise prep for stable arcs
- 🔥 Electrode Ovens & Quivers — keep filler rods and electrodes in peak condition
- 💡 TIG Welders — from workshop to industrial machines
✅ With the right knowledge and the right kit, every TIG weld can be strong, clean, and visually flawless.