The Complete Buyer’s Guide to TIG Welding (GTAW): Process, Settings, Comparisons, and Sourcing Checklist

TIG welding (also called GTAW) is the go-to process when you need ultra-clean, precise, and cosmetically smooth welds on metals like aluminum, stainless steel, and titanium. This guide gives you exactly what buyers and practitioners need up front: when to choose tig welding, the right gas and machine features, starter settings for aluminum and stainless, how it compares to MIG/Stick/Laser, and a practical sourcing checklist (especially for China-based OEMs). Use this as your playbook to select equipment, set parameters, qualify suppliers, and hit spec on day one.

What Is TIG Welding (GTAW) and When to Use It

TIG (Tungsten Inert Gas) welding—formally Gas Tungsten Arc Welding (GTAW)—uses a non-consumable tungsten electrode and inert shielding gas (typically argon) to create a precise, controllable arc. Filler metal is optional and added separately.
Use TIG when you need:

High-precision, clean welds with minimal spatter and distortion

Superior control on thin gauge materials and small parts

Aesthetically critical beads (e.g., visible stainless tubing, frames, jewelry)

Non-ferrous metals (aluminum, magnesium), reactive alloys (titanium), and stainless steel

Avoid TIG when maximum deposition rate or heavy production speed is the priority—MIG or SAW may be more economical there.

TIG Welding Process Steps and Core Settings

Steps

Prepare base metal (degrease, remove oxides—stainless passivation or aluminum oxide removal).

Select tungsten type/size and grind a consistent tip shape.

Set AC/DC, amperage, pulse (if used), pre/post-flow, and balance (for AC).

Purge (if required for stainless pipe/tube).

Establish arc (HF start or lift), control puddle, add filler as needed.

Maintain gas coverage until crater fill and cool-down complete.

Key Settings

Start Method: HF start preferred for clean arc initiation.

Torch Cooling: Air-cooled for ≤200–250 A intermittent; water-cooled for higher duty cycles.

Foot Pedal/Remote: Enables dynamic amperage control—critical for thin materials.

Pulsed TIG: Useful for heat input control and bead consistency on thin parts.

Gas Pre/Post-Flow: Typical pre 0.2–0.7 s; post 5–12 s depending on tungsten size/heat.

Safety Precautions for TIG Welding

PPE: Auto-darkening helmet (≥DIN 10–12 as needed), flame-resistant gloves/jacket, eye/skin protection from UV/IR.

Ventilation: Control ozone and metal fumes; use local extraction when needed.

High Frequency (HF): Proper grounding to avoid interference/electrical risks.

Shielding Gas Handling: Secure cylinders, check regulators/leaks.

Hot Work Permits/Fire Safety: Keep area clear of combustibles, have extinguishers present.

Shielding Gas Selection Guide (Argon vs Helium and Mixes)

100% Argon (most common): Stable arc start, good puddle control, excellent for stainless and aluminum.

Argon/Helium Mix (e.g., Ar/He 75/25 → 25/75): Higher heat input, deeper penetration, faster travel on thick copper/aluminum; costs more.

Back Purge (stainless/titanium tubes): Maintain <100 ppm O₂ on root side to prevent sugaring/oxidation.

Flow Rates: ~10–20 CFH for standard cups; increase for larger cups or gas lenses.

Material-Specific TIG Settings and Tips

Aluminum (AC TIG)

Polarity: AC with balance ~65–75% EN (electrode negative) for cleaning/penetration balance.

Tungsten: 2% lanthanated or ceriated; slightly rounded tip for AC.

Filler: 4043 (general) or 5356 (higher strength/harder).

Start Points: 1 A per 0.001" thickness (25 A per 0.25 mm) as a rough rule; adjust with pedal.

Prep: Remove oxide layer mechanically and with solvent; keep dry.

Stainless Steel Pipe/Sheet (DCEN)

Polarity: DC electrode negative.

Tungsten: 2% thoriated/lanthanated; sharp ground tip.

Filler: ER308L (304), ER316L (316), ER309L (dissimilar).

Purge: For pipe/tube, use trailing shield and back purge to prevent sugaring.

Heat Control: Consider pulse (e.g., 1–2 Hz) to limit distortion and heat tint.

TIG Welding Equipment Selection for Home and Industry

Core Features to Evaluate

AC/DC Capability: AC required for aluminum; DC for steels and stainless.

Amperage & Duty Cycle: Match to material thickness and production duty; look for honest specs at 40 °C.

Power Input: 120/240 V dual-voltage for flexibility; 3-phase for industrial loads.

Start & Controls: HF start, 2T/4T torch switch, foot pedal/hand control, adjustable slope in/out, pre/post gas.

Pulsed TIG: Manual or programmable pulses for thin materials and repeatability.

Inverter Topology: IGBT inverters for efficiency, lighter weight, and stable arcs.

Torch System: Air vs water-cooled; availability of flex heads, gas lens kits, and quick connects.

Accessories Included: Regulators, pedal, torches, ground leads, consumables starter kit.

After-Sales: Warranty (≥2–3 years), service centers, spare parts availability.

Portable TIG Machines

Ideal for field service and light fabrication—prioritize weight (<20 kg), dual-voltage, robust casing, and stable HF start.

MIG vs TIG vs Stick vs Laser — Which to Choose and Why

TIG vs MIG: TIG = slowest, cleanest, most precise; MIG = fastest deposition, easier for production/fabrication.

TIG vs Stick (SMAW): TIG excels on thin/non-ferrous and appearance; Stick is rugged, low-cost, great outdoors.

TIG vs Laser: Laser offers ultra-fast, narrow HAZ, high capex; TIG is far cheaper and more flexible for varied joints.

Decision Tips

Need cosmetic, sanitary, or thin-gauge excellence → TIG.

Need speed and volume → MIG.

Outdoor/dirty steel repair → Stick.

High-throughput, automated cells → Consider Laser or MIG with robots.

Application Playbook: Car Exhaust Repair, Jewelry, DIY Projects

Car Exhaust Repair: Thin stainless tubing; DCEN, 1.0–1.6 mm filler, purge the ID, use gas lens #8–#12 for coverage.

Jewelry/Precision Parts: Micro-TIG with low amperage, fine-tip tungsten, and pulse; consider microscope hoods.

DIY Fabrication: Favor dual-voltage compact units, foot pedal control, and pre-set job memories for repeatability.

Sourcing Guide: TIG Welding Machine Suppliers in China

How to Qualify Vendors

Compliance & Certification: ISO 9001, CE/UKCA; request test reports, burn-in procedures, and calibration records.

Spec Validation: Verify duty cycle at rated temperature; test HF start reliability and arc stability.

Component Transparency: Torch brand (WP-17/18/20 series), IGBT supplier, capacitors, water-cooler specs.

QA/QC: Incoming inspection records, final functional tests, serial traceability, firmware versions.

After-Sales: Spare parts lead time, warranty terms (board-level vs whole-unit), regional service partners.

Customization (OEM/ODM): Private labeling, custom firmware profiles (pulse libraries), cable lengths, plug types.

Commercials: MOQ, EXW/FOB pricing, lead time, packaging tests (ISTA 1A/2A), Incoterms, HS code, sample availability.

Supplier Screening Checklist

Request a live video FAT (Factory Acceptance Test) on AC aluminum and DC stainless.

Evaluate ripple current, arc stability at low amps (<10 A), and pedal responsiveness.

Confirm real duty cycle with thermal trip demo.

Inspect torch/consumables compatibility and spares list.

Lock in SLA for RMA turnaround and spare boards.

Finding Industrial TIG Welding Services Near You

Search for ASME Section IX/Welder Qualifications or ISO 3834 certified shops.

Request WPS/PQR documentation, sample coupons, and NDT capabilities (PT/VT/X-ray if needed).

Audit purge workflows for stainless/titanium jobs and traceability for critical parts.

Compare lead time, fixture capability, and jig design support for repeatability.

Cost of Ownership and ROI

Capex: $500–$1,500 (hobby/entry) → $2,000–$6,000 (pro portable) → $6,000–$15,000+ (industrial).

Opex: Shielding gas, tungsten, cups/gas lenses, filler rods, power; water-cooler maintenance if used.

Throughput vs Quality: TIG is slower; ROI hinges on rework reduction, cosmetic spec hits, and higher selling price.

Consumables Strategy: Gas lens kits reduce gas flow for the same coverage over time, improving bead quality and cost.

Consumables, Accessories, and Maintenance

Tungsten Electrodes:

2% Thoriated (DC steel; radioactive—handle with care),

2% Lanthanated (versatile AC/DC),

Ceriated (low-amp starts, thin work).

Cup Sizes: #4–#12; larger with gas lens for better shielding on stainless.

Filler Rods: Match base alloy; keep rod clean and dry in sealed tubes.

Maintenance: Keep collets tight, check gas leaks, regrind tungsten frequently, replace cracked cups, service water coolers.

Quality Control, Testing, and Standards

Standards: AWS D1.1 (structural steel), AWS D17.1 (aerospace), ASME Section IX (pressure), ISO 9606 (welder qual.), ISO 3834 (welding quality).

Procedures: WPS/PQR with parameter windows; record heat input for critical alloys.

Inspection: VT/PT common; RT/UT/X-ray for critical joints; monitor color/heat tint on stainless (aim for straw or lighter).

Documentation: Material certs, purge logs, welder continuity records, calibration certificates.

FAQ: Quick Answers

TIG or MIG for aluminum? TIG for thin/high cosmetic; MIG for faster production.

Why porosity? Contamination, inadequate gas coverage, or damp filler. Clean and increase post-flow/gas lens.

Blue vs straw color on stainless? Heat tint indicates oxidation; keep purge/trailing shield and reduce heat input.

Do I need water cooling? For sustained >200 A or long duty cycles, yes.