TIG Welding: The Complete Guide to Better Metal Joining

Introduction

Are you looking for clean, strong welds that look good? TIG welding might be just what you need. But finding good TIG welding help can be hard.

At Istar Machining, we know TIG welding is important for many custom cnc machining projects. We will show you all about it in simple words.

This guide will help you learn TIG welding from start to finish. We will use easy words and share tips from our shop floor.

What is TIG Welding?

TIG welding (also called GTAW or Heliarc) uses a tungsten rod that does not melt. It makes an arc that melts the metal. You can add filler metal if you need to.

Problem: Many shops use wrong welding types for thin or special metals. This makes the welds look bad and break easy.

Solution: TIG welding gives the best control and cleanest welds for thin metal.

TIG welding started in the 1940s as “Heliarc” and was used to join airplane parts in World War II. Now it is used in:

• Making airplanes
• Building cars
• Making art
• Nuclear work

Why Pick TIG Welding?

TIG welding is best when you need:

1. Clean welds – No spatter or smoke
2. Strong joins – Tests show TIG welds are up to 95% as strong as the base metal
3. Pretty welds – Looks like stacked dimes when done right

Problem: Other welding types make ugly welds that need lots of clean-up work. This costs you time and money.

Solution: Our CNC parts machining team at Istar Machining uses TIG welding for the best finish that needs no extra work.

Some good things about TIG welding:

But TIG has some bad points too:

• Slower than other types
• Takes more skill to learn
• Costs more to buy the tools

TIG Welding Tools You Need

To start TIG welding, you need these tools:

1. TIG Welder Machine

Pick AC/DC if you want to weld aluminum. DC-only is fine for steel and stainless.

2. Shielding Gas

Problem: Wrong gas makes bad welds with holes and weak spots. This makes parts fail when you need them most.

Solution: At Istar Machining, we use pure argon for most jobs, or argon-helium mix for thick aluminum in our aluminum CNC machining work.

Gas flow should be 15-20 cubic feet per hour for most work.

3. Tungsten Electrodes

These come in different types:

• Red (2% thoriated) – Works well but slightly radioactive
• Blue (2% lanthanated) – Good all-around choice
• Gold (1.5% lanthanated) – Great for AC welding

4. Filler Rods

Pick the right rod for your metal:

• ER70S for mild steel
• ER308L for stainless steel
• ER4043 for aluminum

5. Safety Gear

Never weld without these!

• Auto-darkening helmet
• Leather gloves
• Long sleeves
• Proper air flow

Step-by-Step TIG Welding

Problem: Bad setup leads to failed welds and wasted time. This means you have to start over or scrap parts.

Solution: Follow our proven setup steps that we use in our precision CNC machining shop at Istar Machining:

1. Clean your metal – TIG hates dirt and oil
2. Set up your machine:
   • DC for steel and stainless
   • AC for aluminum
   • Start at 1 amp per .001″ of metal thickness
3. Check your tungsten – Sharp point for DC, ball end for AC
4. Gas flow – 15-20 CFH (cubic feet per hour)
5. Practice arc starts – Start 1/8″ from the metal
6. Move in a steady line – Walking the cup helps
7. Add filler at a low angle – 15-20 degrees is best

TIG Welding Uses

TIG welding works best for these jobs:

Stainless Steel Pipes

Problem: Food, drug, and drink makers need clean, rust-proof welds. Germs can grow in bad welds, causing recalls and danger.

Solution: Our steel CNC machining team at Istar Machining uses TIG for the cleanest welds that pass all FDA tests.

TIG creates “sanitary” welds needed for:

• Milk pipes
• Beer tanks
• Drug tubes
• Food tools

Aerospace Parts

Planes and space ships need perfect welds that are:

• Light weight
• Very strong
• Crack-free
• Able to handle big heat changes

TIG is the only good choice for thin titanium and special aluminum alloys.

Car Parts

TIG works great for:

• Roll cages
• Exhaust pipes
• Intake tubes
• Custom frames

Art Projects

Many metal artists use TIG for:

• Stainless sculptures
• Copper art
• Custom bikes
• Furniture

Pro Tips for Beginners

If you’re just starting with TIG, try these tips:

1. Start with no filler – Just melt the edges together
2. Use a gas lens – Shows more of your work
3. Rest your hand – Steady hands make better welds
4. Use clamps – Hold parts still for better welds
5. Post-flow gas – Keep gas flowing 5-10 seconds after you stop

Problem: New welders rush and make bad welds. This wastes metal and time.

Solution: At Istar Machining, we train welders to go slow and steady for perfect results, just like in our 5-axis machining work where speed ruins precision.

TIG Welding Safety

TIG is safer than some welding types but still has risks:

1. Arc flash – Can burn your eyes
2. Gas dangers – Argon can push out air you need
3. Heat burns – Metal stays hot after welding
4. Fumes – Need good air flow

Make sure you have:

• Auto-darkening helmet (shade 9-13)
• Leather gloves that go past your wrists
• No gaps in your clothes
• Fan or vent to move air

Special TIG Methods

After you learn the basics, try these:

1. Pulse Welding

The machine turns power up and down quickly. This helps with:

• Less heat in the part
• Less warping
• Better control

2. Back Purging

Putting gas on both sides of stainless steel stops the back from turning brown.

3. Walking the Cup

Moving the ceramic cup in a small circle makes very neat welds.

Problem: Standard TIG methods can’t handle all job types. This limits what you can make.

Solution: At Istar Machining, we train in all TIG methods so our CNC welding can handle any job you bring us.

TIG vs. MIG: What’s Best?

TIG and MIG both join metal but work very differently:

Problem: Using the wrong weld type wastes time and money. This cuts into your profits.

Solution: Istar Machining helps pick the right process for each job. Sometimes we even combine TIG with our CNC turning for parts that need both processes.

The Market for TIG Welding

The welding market is growing fast, set to reach $32.7 billion by 2030. TIG welding is a key part of this growth.

Top industries using TIG welding:

1. Aerospace (65% of aircraft parts use TIG)
2. Food processing
3. Medical tools
4. Art and custom cars

Only 15% of welders are fully trained in TIG, making it a special skill.

Common TIG Welding Questions

Work With Istar Machining

Problem: Finding shops with both TIG welding and CNC machining skills is hard. This means dealing with multiple shops for one project.

Solution: Istar Machining offers both top-level TIG welding and CNC machining services under one roof.

Our team has the skills to make your parts from start to finish. We use TIG welding for the cleanest, strongest joints on all metals.

When you need parts that are both machined and welded, call us for a quote.