TIG guide
TIG Welding: Precision, Stainless and Aluminium
TIG is the connoisseur's process: slower, harder, and capable of welds you'd photograph — which is why Australian stainless benches, food-grade gear and ally boat work all go TIG.
What is TIG welding?
TIG welding (GTAW — Gas tungsten Arc Welding) — a non-consumable tungsten electrode arcs under pure argon while you hand-feed filler rod. It's the hardest common process to master — both hands and one foot and its natural territory is stainless steel, aluminium, thin material.
TIG is the connoisseur's process: slower, harder, and capable of welds you'd photograph — which is why Australian stainless benches, food-grade gear and ally boat work all go TIG.
How the process works
An electric arc between the electrode and the work delivers intense, localized heat; the molten pool is protected by pure argon (100%) — without that shield, air makes the weld porous and brittle. Beyond the physics, the operator controls heat, travel speed and position; the process rewards consistency over talent.
Settings by thickness
| Thickness (steel) | Current (DCEN) | Tungsten | Filler rod |
|---|---|---|---|
| 1 mm | 30–60 A | 1.6 mm | 1.6 mm |
| 1.5–2 mm | 50–90 A | 1.6–2.4 mm | 1.6–2.4 mm |
| 3 mm | 90–130 A | 2.4 mm | 2.4 mm |
| 6 mm | 150–200 A | 2.4–3.2 mm | 3.2 mm |
Equipment and consumables
What you need beyond the machine: pure argon (100%) where applicable, filler matched to your material, and the safety kit that never gets discounted — helmet, gloves, ventilation. In Australia: Aluminium work in Australia needs an AC-capable TIG — DC-only machines handle steel and stainless only.
Tungsten and prep
2% lanthanated (blue) tungsten is the modern default for DC steel/stainless and AC aluminium alike. Grind radially — lines running the length, like a pencil, never around the circumference — on a dedicated wheel. Tungsten contamination (dipping the tip in the pool) means stop, regrind, restart; welding through it poisons the weld.
Aluminium on AC
Aluminium needs AC: the electrode-positive half-cycles blast the oxide layer clean while the electrode-negative half puts heat into the work. Modern inverters let you set balance (roughly 60–75% EN for most work) and output frequency (around 120–200 Hz tightens the arc for fillets). More current per millimetre than steel — aluminium dumps heat into the job — and zero warning before blow-through: the dull oxide hides a pool that's already falling.
Common mistakes
- Dipping the tungsten into the pool — contaminating the electrode and the weld
- Too much torch angle: 10–15° from vertical is plenty
- Forgetten post-flow gas: tungsten oxidises and turns black as it cools
- Grinding tungsten lengthwise instead of radially — arc wanders
Watch: curated video walkthroughs
We curate the clearest publicly-available walkthroughs for this guide's core skills.
Frequently asked questions
How does tig welding work?
TIG welding (GTAW — Gas Tungsten Arc Welding): a non-consumable tungsten electrode arcs under pure argon while you hand-feed filler rod. It's the quality benchmark where appearance, control or exotic metals matter.
What is tig welding used for?
TIG welding is used for stainless steel, aluminium, thin material and visible/structural quality welds. In Australian terms: stainless benches, food-grade gear, aluminium boat and 4x4 work, and anything visible.
How hard is tig welding to learn?
Expect a week of ugly beads before it clicks.
What gas does tig welding use?
TIG welding uses pure argon (100%).
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