Best Practices for TIG Welding 1/4-inch (or thinner) Materials

From light fabrication to processing pipe and aerospace, thin is infor materials that is. Due to certain weight, space and design requirements, applications in these industries frequently call for materials like stainless steel and mild steel or aluminum that are inch and thinner. These applications, too, often require the TIG process. TIG creates a narrower heat-affected zone (or HAZ, the area between the weld deposit and the base metal ) compared to other welding processes. This is important, because the less heat generated when welding thin materials, the less chance of problems like burn through or warping.

Welding on 1/4 inch and thinner metal requires caution to prevent burn-through and other problems.
Other issues that can arise when welding inch or thinner materials include starting or stopping porosity and pinholes, small areas in the weld caused by gas entrapment from either the atmosphere or the shielding gas. Some materials, like stainless steel tend to buckle and crack if there is too much heat. While there are solutions to the above issues, the goal in TIG welding thin materials is to prevent the problems in the first place. A few best practices can help. Power Up Aluminum that is inch or thinner is best welded with an AC inverter with squarewave technology. This type of power source provides a narrow and focused arc with fast response; when the foot pedal is pressed the arc initiates almost immediately. This feature minimizes the heat input into the material and lessens the chance of burn through. These inverters also offer continuous high-frequency arc starts, which help sustain the arc at the necessary low beginning amperages. Aluminum can also be TIG welded using a power source with pulsing capabilities. By definition, pulsing means varying the current from a high peak amperage level to a lower

background amperage level at regular intervals,1 and it is another means of minimizing heat input. If you have a power source with pulsing capabilities, contact the manufacturer or your welding distributor for the recommended settings. Training is key to obtain the best results with pulsing. Maintaining the correct parameters is also crucial when AC welding thin aluminum. A range of three to 200 amps is recommended. Keep the amperage setting toward the low end for aluminum ranging from 0.040 to 0.060-inch thick and increase accordingly toward 200 amps for aluminum closer to -inch thick. Set the balance control toward the electrode positive (EP), around 60 percent. This will provide ideal cleaning action to remove the oxide layer found on aluminum. The oxide layer has a higher melting temperature than the base aluminum materialaluminum oxides melt at approximately 3,600 degrees F, and the aluminum melts at 1260 degrees F. For that reason, the aluminum is more prone to burn through if the oxide layer is not removed (once you melt through that layer, there will be more heat than necessary to weld the aluminum itself). To TIG weld materials like thin stainless steel or mild steel, you should choose a DC power source with high frequency arc starting capabilities. Both a standard DC power source or an inverter-based machine will provide good results, but an inverter again offers reliable low amperage arc starts and a narrow, focused arc to lessen burn through. Set either type of machine on straight polarity (DCEN, or direct current electrode negative). The recommended amperage range for DC welding thin mild or stainless steel is one to 200 amps. Be Choosey A pointed 2-percent ceriated is recommended for welding -inch and thinner materials. Ceriated tungsten provides good arc starting at low amperages and it also provides reliable arc stability in both AC and DC modes. For materials 14-gauge (0.07470 inch) to 30-gauge (0.00120 inch), choose a 1/16-inch diameter tungsten. A 3/32-inch diameter tungsten will work better for materials 12 gauge (0.146 inch) up to -inch thick.

Properly grinding the tungsten prevents arc wandering and other problems that can cause weld discontinuities.

When grinding your tungsten to a point, take care to do so lengthwise. Do not grind around the end of the tungsten as it creates ridges that can cause arc wandering. Also, remember to use a grinding wheel (250 grit or finer) designated for the intended purpose to avoid contamination that can lead to arc trouble or weld discontinuities. The type of filler metal you choose will depend on the type of material you are welding more so than how thin it is. However, because less filler metal is needed to weld thinner material you should choose a smaller diameter rod. For example, when TIG welding very thin materials (.010- to .060 inch), choose a 1/16-inch diameter rod. For slightly thicker materials (up to 1/4 inch), use a 3/32-inch diameter filler metal. Both diameters are available in industry-standard cut-lengths of 36 inches for TIG welding on most any type of material.

As an example, the two most common filler metal choices for AC GTAW welding aluminum are ER4043 and ER5356. There are several types of filler metals for DC GTAW welding stainless steel. The one you choose will depend on the specific AISI stainless steel type. For example, AISI 301, 302 (L), 303 and 308 stainless steel require ER308 filler metal, whereas 309 materials require ER309 filler metal. ER316 and ER316L filler metals are also common and are used for AISI 316 and 316L stainless steel. See Figure 2 for additional recommendations. Mild steel typically requires ER70S-6 filler metal. As a side note, in all instances, ER indicates that the filler metal is designed for the TIG process. Next, choose the right torch for your thin material application. A 200-amp (maximum) TIG torch is sufficient for welding -inch and thinner materials, and is available in air- or watercooled models. Which torch you choose will depend in part on the location of the welding, in part on personal preference and finally, on the equipment available. Air-cooled TIG torches are less expensive than water-cooled torches and do not require an additional water cooler, which makes them highly portable. However, they tend to be a bit heavier and larger, and may be more difficult to maneuver. Choose one in the 150-amp range, as it will be slightly lighter and easier to control on thin materials. If you have access to a power source with an integrated water cooler, or a separate one, using a water-cooled torch offers the advantage of a smaller handle and body, lighter weight and the ability to reach into smaller or difficult-to-reach joints. With either torch, consider using a gas lens as added protection against problems like pinholes or starting porosity. A gas lens replaces the collet body that is standard in a torch and helps improve shielding gas coverage. A typical gas lens is composed of a copper and/or brass body with layered mesh screens of stainless steel that helps evenly distribute the shielding gas around the tungsten and along the weld puddle. Fixed on Success Final steps that can help ensure welding success on thin materials include proper joint preparation, fixturing (when needed) and some good, basic TIG techniques. First, when AC welding on thin aluminum it is common to create either a butt, lap or inside outside corner joint. Thin materials that are DC TIG welded, on the other hand, tend to encompass a wider range of configurations, including fillet welds, outside corners or pipe bevel joints. In all instances, the tolerances must be tight to prevent problems.

Figure 2
For example, gaps between two pieces of thin material would automatically require more filler metal to fill in the space and create a sound weld. This addition of filler metal requires more heat to melt it, which in turn can cause burn through or warping on thinner materials. To minimize the problem, make certain that the joint to be welded fits tightly together. If necessary, place small tack welds along the joint to keep it together or clamp the materials together. In the case of higher production applications that require repeatable welds, fixturing may be a viable option. For smaller parts, stick to good joint preparation and tack welds as a best precaution. Finally, use the same reliable TIG techniques for welding -inch or thinner materials as you would for thicker ones. Be certain to find a comfortable position in which to TIG weld, brace yourself against a table or the work piece if needed and hold the torch in a way that offers the most control. Many welding operators prefer to hold the torch like a pencil. A torch angle of five to 20 degrees perpendicular to the base material offers good visual control over travel speeds and keeps shielding gas coverage and arc length at an optimum. Hold the torch approximately 1/8 inch away from the base material to maintain a focused, stable arc. The trick, especially when TIG welding thin materials, is to keep the arc length consistent so that it doesnt wander or become too broad, both factors that can lead to excess heat and/or to poor weld results. Practice is the best recommendation for achieving this consistency.

A steady travel speed is also important when welding thin materials, as lingering too much in one area can cause heat to build up and increase the chances of burning through the material. It will also create an unnecessarily wide weld bead. Use the push technique, moving the torch so that the weld puddle is always visible and ahead of the torch. A good rule of thumb is to move the torch and add filler metal at a pace that creates a weld approximately twice the size of the tungsten being used. This travel speed will also ensure good shielding gas coverage for top-quality welds on thin materials. If ever in doubt about these techniques or any other aspects of welding thin materials, contact a trusted welding distributor or welding product manufacturer for best recommendations.