There are many best methods to fuse metals by welding through various methods. Among many options are MIG and TIG — MIG stands for Metal Inert Gas and Tungsten Inert Gas. The debate over which method is the best-doing rounds for quite some time now. Each method has its benefits, given the nature of the work/project.
To compare the two, let us help you understand MIG welding and TIG welding. We will additionally look into their differences and ultimately choose which is better.
What is MIG?
Metal Inert Gas welding or MIG welding is the popular and easy welding process. A consumable wire electrode is needed to create an electrical arc between the item being welded and the consumable wire doing the welding. The metal rod is used as an electrode and also as a filling material.
Once the metal heats up and the welding process begins, the welding gun releases inert gas from the gas nozzle to keep the contaminants away. The gas is the combination of CO2 and Argon.
Tungsten Inert Gas welding or TIG welding is named because of the tungsten electrode inside the welding. Since the tungsten doesn’t readily melt, it conducts the electricity arc directly to the components you need to fuse. In other words, the wire is held by the operator that is touched to the electrode to melt into the base item.
TIG welding, or Tungsten Inert Gas welding, is very similar to MIG welding. TIG still relies on a wire to feed and heat up to melt the base item and wire to form the weld.
There are various MIG welding applications, and before that, one has to gauge how a particular welding process fits the project. For instance, when working on thicker metals, the filler used in MIG welding will firmly hold the parts.
MIG welding is versatile and can be used on a wide variety of projects as long as the welder matches the gas and wire to the types of metal he/she needs to conjoin.
Here are some of the examples of MIG applications:
Metal component repairs
Automotive repairs and manufacturing
Trailer hitches
Farming equipment
Construction welding
Pipe welding
Underwater welding projects
Railroad track repair
Shipbuilding
TIG Welding
For a work that requires precision, TIG welding is the top choice. It can be used on various metals (steel, bronze, nickel, brass, copper, gold, etc.), which is why the process is applied in diverse industries, helping create and repair many items.
This welding process is known for its strength and precision.
Here are some of the examples of industries that use TIG welding –
Aircrafts & Spaceships
Automobile
Industrial fixtures
Metal sculptures
Which one is better — MIG or TIG?
Although the process may seem similar, some differences set the processes apart. For instance, MIG uses a consumable wire, whereas TIG uses a tungsten electrode that isn’t consumable.
Now, each welding process has its usage that best fits them; that is where the difference lies. If you want speed over accuracy, MIG is for you, and if you choose the latter, TIG can give you the best results. TIG welding is more suitable for thinner metals, and MIG welds work well with extensive projects with thick metals.
Your better understanding of the MIG and TIG welding process will help you make an informed choice when working on the project.
TIG welding is difficult even under the best of circumstances. It is a skill that requires experience, coordination and a great deal of multitasking expertise. By adding stainless steel as a source workpiece to the mixture, the entire process becomes even more difficult to accomplish with any degree of precision.
Often, employers hire TIG welding professionals to work on stainless steel. It makes sense to do so. Granted, this action may hinder upcoming projects, but the long-term benefits are undeniable. After all, stainless steel welding is not uncommon. It’s a common metal, a hard, structurally dense alloy that has permeated all corners of life. The work done on such projects is not marred by substandard welding. A poorly welded stainless steel structure may even warp or rust from the weld’s heat. What an unforgivable sin that would be.
Crucial Applications of Stainless Steel in Welding
Stainless steel is not a single metal. It is actually a versatile family of alloys found everywhere. This includes the construction industry, pressure vessels and piping systems. In addition, its ductility and strength make it ideal for large construction projects that require a strong and durable support material.
Even kitchenware and food industry components use certain stainless steel. Corrosion-resistant and chemically neutral grades are favored for such commercial applications. In oil fields and other harsh industrial environments, ANSI and SAE-graded steels offer excellent heat resistance and durability, as well as a degree of resistance to liquid/gas corrosion. So what’s the answer? What are the options when stainless steel workpieces need to be welded? There are many well-known brands of TIG welders on the market to choose from, but even with such a great machine, someone needs to overcome the challenges associated with welding stainless steel.
The First Steps to Mastering TIG Welding of Stainless Steel
The problem is that the alloy contains a large number of graded amalgams. Trace amounts of the metal are added at the heat treatment stage in order to create many members of this metal family. Additives such as nickel and manganese provide unique mechanical and chemical properties to various stainless steel grades. The point is: that while engineers and builders want these properties to be realized, they can complicate TIG welding operations.
It is the job of the TIG welding professional to understand these alloy properties and to know and apply techniques specifically for stainless steel. Equipment selection and setup are also important, but the true professional knows that the first step needs to be performed before applying these requirements to the job. Cleaning and preparation, which is key, is the means to unlocking the entire process.
Preparation Process Guide:
Cleaning metal surfaces of grease, oil, corrosion and other contaminants
Further preparation. Smooth the surface using wire brushes and abrasive tools
Select a suitable inert gas. Hot stainless steel heat affected zones tend to oxidize
Choose a good quality welder.
Applying Professionally Tuned Equipment Settings
Intermediate welders are competent, but tend to take shortcuts. Maybe they’re experienced and think they know everything there is to know about TIG welding, and there may be some truth to their claims, but equipment changes are always changing. At Welding Town, we’re also committed to providing more power, more flexibility, and more features. Professionals know this, which is why they are careful to keep their equipment manuals handy for reference.
Many welder factories provide data sheets so that welders can get the most out of their equipment. On that table, it’s easy to intuitively see the ideal equipment setup. The amperage and voltage are there to better ensure deep root fusion. Electrode polarity and filler metal selection are also clearly printed. Tungsten cleaning and sharpening, duty cycle settings, and amount of protective gas – all of these variables are controllable. This is where the multitasking aspect stands out and allows professional welders to adjust many settings with confidence.
By the way, reviewing the manual, there is a troubleshooting guide in the back of the book. It will keep seasoned welding professionals on the straight and narrow if unforeseen problems arise during stainless steel welding operations.
Here are some tips and tricks to help professionals avoid common pitfalls when looking for quality, professional results:
Use the correct diameter tungsten rod (see manual datasheet)
Keep tungsten electrodes clean and sharp
Use 100% argon as a protective gas
Manage application heat
Establishing a good, clean electrical ground
Use DCEN (Direct Current Negative)
A Return To The Basics: TIG Welding For Stainless Steel Projects
TIG welding, or tungsten inert gas welding, is a versatile type of arc welding that uses tungsten electrodes and inert argon gas to create a weld pool. It’s suitable for stainless steel because TIG welding machines produce precise, clean welds. However, and this is the main reason for writing this article, TIG welding also requires a lot of skill and practice, as well as proper equipment and settings. So far, the Tooliom TL-200T has been recommended as an ideal partner for pro TIG welders, especially when the workpiece is made of stainless steel. The Tooliom TL-200M is also available, and it adds MIG (Metal Inert Gas) welding capabilities into the mix.
TIG welding or tungsten inert gas welding is a versatile type of arc welding that uses a tungsten electrode and inert argon gas to form a weld pool. It is suitable for stainless steel because TIG welding machines produce precise, clean welds. However, and this is the main reason for writing this article, TIG welding also requires a great deal of skill and practice, as well as proper equipment and setup. So far, the TIG-200P has been recommended as the ideal partner for professional TIG welders, especially when the workpiece is made of stainless steel.
Regardless of which machine the welder chooses, there are a few other things that need to be taken care of before starting the arc. As mentioned earlier, the workpiece needs to be prepared. Select, clean and sharpen the proper tungsten electrode. Is the arc circuit set up correctly? A professional welder will check this by adjusting the current and voltage, followed by a quick check that the grounding clamp is tight. Finally, argon gas flows around the weld pool as set by the regulator. The welder is protected by wearing gloves and a welding helmet, as well as any other flame-retardant clothing.
At this point, there are a lot of things to manage. Controls, gas regulators, arc consistency and melt pool size, all need to be carefully monitored. One way to simplify things slightly is to add a foot pedal. Machine presets are also available from the machine control panel, but they need to be fine-tuned on-the-fly as the electrode’s travel speed across the weld changes.
Once the DCEN (DC Negative) setting is correctly locked, the cables are connected in the correct configuration, all safety measures are in place, and work can begin.
Managing The In-Action TIG Welding Process
The goal now is to lay a clean, spatter-free joint. The melting process should be deep to the root, the electrode should move quickly, and the surface appearance of the weld should meet the requirements of the welding inspector. With no oxidation, little discoloration, and no workpiece warpage, the end result is clean and structurally sound.
There is no reason why these goals cannot be achieved. If the welder and preparation have been done correctly, the only remaining issue is the skill of the welder. This person must be well versed in the unique challenges encountered when using a TIG welder on a stainless steel project. Training is important here, as it has been experienced on past projects concerning this potentially difficult to weld alloy. Remember, stainless steel parts are common. They are especially common in structural work, engineering projects, and piping work. Austenitic stainless steels are popular. They are a class of alloys that can be welded, but their microcrystalline structure changes if exposed to a lot of heat.
Now, austenitic steels will absorb a lot of heat due to weld geometry issues and the corresponding reduction in travel speed. Professional welders should be aware of this problem. If the metal cannot dissipate this energy, it will deform. The alloy is rich in chromium, which is inherently corrosion-resistant, but if the weld temperature is too high, the trace element may be depleted. The problem of chromium depletion in stainless steel usually manifests itself as corrosion.
When it comes down to it, stainless steel parts have a very good insulation mechanism. And they cannot easily dissipate that heat. Corrosion problems, warping, chromium depletion and alloy embrittlement are all possible if the job is not done properly. Welding specialists can certainly solve these problems, but when other stainless steel families are added, this skill becomes increasingly difficult to master. Austenitic alloys are one such group, along with ferritic, duplex and martensitic steels. Unfortunately, this is a large number of graded stainless steels, all of which have their own mechanical and physical properties, all of which react in some way to large amounts of heat.
Solving Stainless Steel Weldability Complications
By maintaining travel speed, most problems can be solved immediately. There is no heat buildup and the small amount of heat present in the weld will dissipate without changing the microcrystalline structure of the alloy. Using the correct filler metal is also critical. If the grade of stainless steel is known, such as 316 austenitic stainless steel, a matching 316L filler will be selected. Similarly, this time a martensitic alloy is used, a stainless steel that contains more carbon. It is one of the most difficult alloys to weld and is prone to hydrogen cracking. Professional welders address these issues through the use of preheat work, matched filler and heat treatment.
Frankly, welders are not chemists and they should not understand the changes that occur when the microcrystalline structure of an austenitic or martensitic alloy is transformed in some unfavorable way. They do, however, have an intimate knowledge of welding equipment, which means they can regulate travel speeds and the amount of heat that remains in the HAZ (heat affected zone). As a result, the settings entered by the professionals will ensure satisfactory travel speeds, and they will also use the proper filler. All in all, when professionals work on stainless steel welding projects, it is absolutely possible to achieve a non-porous weld that goes down to the root.
Even though all these stainless steel welding factors may seem very complicated, there is a silver lining. Yes, professional welders are prioritized here, and top-notch welding machines such as the MIG/Stick/TIG Multi-Process Welder Trio are also prioritized, but there is also an element of common sense. Imagine a stainless steel job on some part of a large project that goes smoothly and without incident. There is a carbon steel plant nearby. There may be a temptation to share tools. Don’t do it. By sharing tools between two jobs, iron may be introduced into the stainless steel weldment, thus inserting a source of rust into an otherwise clean joint. It’s common sense, and it’s a powerful tool.
Beyond simple common sense, this requires careful and good work. There are too many grades of stainless steel to customize a weld setup plan for each grade. Instead, a professionally executed stainless steel work plan should be implemented. Be sure to maintain a well-regulated travel speed setting. Do the same for filler metal and shielding gas; keep matching filler on hand and always use 100% inert argon. A DC electrode negative arc is a must, along with the associated current and voltage settings, to achieve narrow, precisely applied weld path widths.
In short, don’t be intimidated by alloying problems. A powerful TIG welder can produce precise, clean welds as long as the welder is a professional and familiar with these unique challenges. Proper preparation is the first step, along with a judicious equipment setup program. Then it’s a matter of letting experience and training take over. If the training isn’t fully implemented, don’t blame the equipment. Instead, go back to the drawing board and practice, practice, practice.
It’s worth noting that since this article is coming to a close, implementing a good TIG training program will be easier, but replacing expensive stainless steel parts won’t be so easy if warpage or corrosion occurs due to substandard welding practices.
TIG welding stainless steel like a pro – FAQs
What are some application scenarios for stainless steel?
Stainless steel is used in the construction industry, pressure vessels and piping systems. In addition, its ductility and strength make it ideal for large construction projects that require a strong and durable support material.
What is the first step in mastering stainless steel TIG welding techniques and how do I do it? Cleaning and preparation.
Remove grease, oil, corrosion and other contaminants from metal surfaces
Further preparation. Smooth the surface with wire brushes and abrasive tools
Choose the right inert gas. The heat affected zone of hot stainless steel oxidizes easily
Choose a good quality welder.
How to avoid some mistakes (pitfalls) for high quality results? Use the correct diameter tungsten rod
Keep the tungsten electrode clean and sharp
Using 100% argon as a shielding gas
Manage application heat
Establishing a good, clean electrical ground
Use DCEN (Direct Current Negative)
If you’ve gotten interested in TIG welding lately, then you probably know that TIG welding is a complicated process to learn. However, it’s also gratifying, and once you get the hang of it, you’ll be creating beautiful metal workpieces in no time at all. Part of learning the process of TIG welding means you’ll need to learn how to set up a TIG welder for mild steel.
So, how do you set up a TIG welder for mild steel? When learning how to TIG weld with mild steel, you will need to take extra time and practice to learn the skill, but you’ll be using Tungsten and Argon gas, just like when you weld most other metals. You will need better gas coverage than what you’ll need when welding other metals, however. You’ll also need to learn the TIG power supply features and TIG welding machine settings.
Since there isn’t a lot of information on the Internet today discussing how to set up a TIG welder for mild steel, we created this article to save you some time. To help you understand how to set up a TIG welder for mild steel, we’ll cover how TIG welding works on mild steel, the TIG power supplies you’ll need, the TIG torch options for welding mild steel, how to set-up your electrode for mild steel, and how you’ll set-up your TIG welding machine for mild steel.
Just looking to weld mild steel, not sure which process to use yet? Check out my article about MIG welding mild steel. Might be worth checking out to get a full picture of how to do the best job for your specific project.
If you’ve already started the process of learning how to TIG weld, then you know that one of the reasons it’s so challenging to learn TIG welding skills is because you use two hands in TIG welding. Plus, TIG is a bit different when compared to other welding processes for steel because of how we create the arc and add the filler material during TIG welding differs.
You need to use two hands when TIG welding because one hand uses the TIG torch that creates the arc, and your other hand adds the filler metal as you are welding joints (a feeder pen can be immensely helpful, especially for beginners and infrequent welders). Since TIG welding means you’ll have to get used to using both your hands at once as you weld, it’s one of the most challenging welding processes to learn. However, when it comes to welding things like mild steel, TIG welding is also very versatile.
While the TIG welding process might also feel slow when compared to other welding options out there, once you learn how to TIG weld, you probably won’t want to stop. That’s because TIG welding creates the best-looking welds around. We find TIG welding often used for welding critical joints, welding a variety of metals including mild steel, and TIG welding also works well for small metal areas.
Using Tungsten to Weld Mild Steel
So, we’ve mentioned “œtungsten” often above, and now we’d like to break it down a bit so that you understand why Tungsten works so well when welding mild steel. Tungsten is the item that gives us TIG welding because, without it, we wouldn’t have TIG welding.
Tungsten is a brittle, hard, somewhat radioactive metal. When you compare Tungsten to other metals, it has a limited use factor. However, it works very well in TIG welding because TIG welding uses Tungsten to create a non-consumable electrode, which also makes our arc in TIG welding. You’ll also find Tungsten used in things like rocket engines, heaters, and light bulbs.
TIG welding and tungsten metal work so well when welding mild steel because the Tungsten keeps the arc with a consistent temperature of 11,000 degrees F. Tungsten brings us a high melting point, and also offers excellent electrical conductivity as you weld, so the tungsten electrode won’t ever burn up.
Tungsten’s unique properties as a metal allow us to make a hotter arc than what we find with the actual melting point of Tungsten. Tungsten’s tensile strength can go up to 500,000 lbs per square inch. Steel, on the other hand, has 36,000 pounds of tensile strength per inch. So, you can see by this comparison why Tungsten works so well on steel when welding.
How TIG Welding Works on Mild Steel
When you are TIG welding with mild steel or any other metal for that matter, you need to have three things. Those three things are heat, shielding, and filler metal. You’ll get the first item, temperature, which is made because electricity goes through the tungsten electrode, creating an arc for you to work with on your project. The second item, shielding, means you’ll need a compressed bottle of gas going into the weld area, and you’ll have to protect that gas from the air. The last item, filler metal, comes from a wire you dip into the arc and melt.
When you are TIG welding, you are trying to bring all three of these things together to create one fantastic, finished final project. We start with the welder turning on the gas flow, which you can usually control using a valve that’s on the TIG torch. Once you’ve done that, you’ll see gas start flowing, which is created to keep the weld area safe from the air. You then take the torch and hold it over the weld joint without touching the metal.
After that, you’ll press a good pedal, and that will start the tungsten electrode’s arc in the TIG torch. Once you’ve created the arc, you’ll see the two pieces of metal will begin to melt and form a puddle of liquid metal. Once you’ve developed your pool, you’ll use your other hand and fill the joint. That means dipping a wielding wire into the arc is so that you can fill the joint. After that, you will have formed one piece of metal.
Now that you understand how TIG welding works on mild steel, we’ll cover some TIG welder power supplies you’ll want to consider when TIG welding with mild steel.
TIG Welder Power Supplies for Mild Steel
When we’re talking about TIG welding power supplies for mild steel, we’re talking about the same things you’ll use for Stick welding power supplies. However, there is a significant difference between a Stick welding power supply and a TIG power supply, and that’s the additional features you’ll find on the TIG welder that allows your torch to TIG weld correctly.
For example, you can use your usual TIG torch on your Stick welding power supply, and you’ll do just fine welding. Both power supplies, the TIG torch, and the Stick welding power supply allow for constant amperage, which is what you’ll need when working with steel. They both help keep the amp rate consistent, and that regulates the heat produced. How much voltage you’ll need will depend on how long your arc is.
Now that we’ve talked about the power supplies you’ll need to know about when TIG welding mild steel, we’ll discuss some of the extra features you’ll find on a TIG power supply versus what you’ll find on regular power supplies when welding mild steel.
Feature #1: TIG High-Frequency Start
Most types of TIG power supplies offer something called a “œhigh-frequency start.” Having a high-frequency start option on a TIG power supply is terrific because you won’t need to physically strike an arc with one of these. Instead, once you use the high-frequency start option on your TIG torch, it will make an arc over a one-inch gap between the metal and the torch. The torch does this by using a quick moment of high voltage with the pressure to help the arc form.
Once you’ve used the “œhigh-frequency start” to form the arc, the voltage starts dropping, and the amps will take over. Having this feature is hugely beneficial because it prevents the Tungsten you are using from getting contaminated. So, you won’t wind up using your Tungsten up as quickly. You’ll also experience less wear and tear on your tungsten electrode over time. That means you’ll have plenty of Tungsten to use while welding your mild steel.
Feature #2: TIG Shielding Gas Pre-Flow and Post-Flow
Other additional features you’ll find on TIG welding power supplies include the pre-flow and post-flow features. You’ll use the pre-flow feature when you want to allow some pre-flow time for your shielding gas to create a shield before you form your arc. On the other hand, the post-flow feature helps keep the gas going for a predetermined time once the arc stops so that the weld is safe until it cools. Since both of these features help keep you safe while welding mild steel, you’ll probably be using them. To make sure gas is properly flowing before welding, a shielding-gas gauge is very handy.
The two most common gases welders use as shielding gases are Argon and Helium. Both of these gasses are Nobel inert gasses, meaning we use them because they don’t alter the characteristics of the weld joint at all.
Some welders like using a mixture of Argon and hydrogen or a combination of Argon and nitrogen. However, when dealing with mild steel, it’s recommended that you use Argon.
Feature #3: AC Waveforms Controls
Another feature you’ll find on your TIG welding power supply is frequency settings. Using these settings, you’ll be able to adjust what you want to see in your welding arc. There are several methods you can use to keep your welding arc running smoothly. With the frequency settings, you can use frequency ranges and other pulses of electricity to modify the arc, so you get what you want. While these settings are essential to know about, you probably won’t be using them often with steel. You’ll more likely use then when welding aluminum or magnesium.
Now, if you don’t have a TIG welder, but you have a stick welder, you can convert your stick welder into a TIG welder for mild steel if you’d like. It’s prevalent for welders to do this. If you’re thinking about converting a stick welder into a TIG welder for mild steel, we’ve got the steps for you below.
Convert a Stick Welder into a TIG Welder for Mild Steel
In the welding world, you’ll frequently find experts using stick welder to TIG weld either carbon or steel pipes. In some cases, welding experts feel that Stick welding supplies perform better than TIG welding power supplies when you are working with mild steel wall pipe.
It’s effortless to convert a Stick welder for TIG welding. All you’ll need is an air-cooled TIG torch and an extra bottle of Argon. After that, you’ll need to follow the steps below:
Swap the polarity to D/C Electrode and negative.
Grab an air-cooled TIG torch. Next, attach it to the electrode holder.
Last, grab your gas supply hose. Hook that hose up to a regulator on one of your bottles of Argon.
Once you’ve completed these steps, you’ve successfully converted your stick welder into a TIG welder.
Now that you understand how to convert your stick welder into a TIG welder, we’ll discuss the voltage types and welding polarities you’ll need to use when welding mild steel.
TIG Welding Voltage Type and Welding Polarities for Mild Steel
When it comes to TIG welding, you’ll find that the same voltage types are used for Stick welding when working on mild steel. Your two voltage types include Direct Current, D/C, and Alternating Current, or AC. D/C Current operates much like a car battery does, and can only flow one way. That one way moves from the negative to the positive. On the other hand, alternating current is also available, and that’s much like the current you’ll find in your own home. A/C can change its current direction several times over a second when needed.
Furthermore, you’ll also discover that TIG welding also uses two polarity types, much like Stick welding, when it comes to utilizing direct current. Those two polarity types include the DC, or Direct Current Electrode Negative, which means the electrode or welding handle is switched to the negative on the circuit, and the electricity goes from the TIG torch to the metal. The DC or Direct Current Electrode Positive means that the electrode or welding handle is switched to the positive circuit, so the electricity flows from the metal to the TIG torch.
The differences in polarity affect how much heat you’ll be applying to the electrode. With D/C Electrode Negative, you’ll get about 66% of the heat in the metal welded. That means you can create a deep penetration weld with this feature. On the other hand, the D/C electrode positive places about 66% of the heat onto the electrode. You’ll be able to complete a shallow weld this way. So, whether you want a deep weld or a shallow weld, you’ll be able to easily use these welding polarities to help you weld mild steel successfully.
How DC TIG Welding Polarity Works for Mild Steel
If you want to comprehend how DC works with mild steel, think about the way water moves. If you grab some water out of the fridge and place it in a glass, the glass getting the water feels the friction. So, the water pitcher in the refrigerator can be considered the negative end, which is giving up the water, and the glass can be looked at as the positive side that is gaining the water. The side getting the water will always be the side with the most friction.
In welding, instead of focusing on who is gaining water, we focus on the side of the heat that’s most concentrated when working with sheet metal. So, D/C power works with heat in welding the same way it does when you move water from a pitcher to a glass. It’s all about friction.
Now that you understand how DC TIG welding polarity works for mild steel, we’ll cover TIG torch types for mild steel, and we’ll move onto the TIG welding machine set-up for working with mild steel.
TIG Torch Types for Mild Steel
If you’ve decided you want to pick out your TIG torch rather than convert one, that’s not a problem. You have two options when it comes to picking out a TIG torch for mild steel. You can select either air-cooled TIG torches or water-cooled TIG torches. We’ll discuss both options in a little more detail below.
Air-cooled TIG Torches for Mild Steel
If you’re shopping on a budget and you want something affordable and practical for working with mild steel, then an air-cooled TIG torch might be your best bet. However, air-cooled TIG torches do have their drawbacks. These torches heat a lot, and part of the problem you’ll notice is that the heat produced by the arc is often wasted. The handle will start feeling hot to the touch after ten to fifteen minutes of welding, meaning you’ll have to stop and take breaks from time to time if you opt for an air-cooled TIG torch for mild steel.
However, if the idea of an air-cooled TIG torch isn’t for you, don’t worry. You do have another option, although it will likely cost you a bit more. However, it might be the better one of the two options for you, depending on precisely what you need.
Water Cooled TIG Torches for Mild Steel
If the first option doesn’t seem right for you, then you can also consider a water-cooled torch to weld mild steel. You’ll wind up with an excellent torch that’s very efficient if you go this route. However, getting this type of torch means you’ll have extra maintenance, and you’ll also have to purchase a TIG torch water cooler along with the torch, too.
TIG Torch Water Coolers for Mild Steel
Anytime you use water-cooled TIG torch, then you’ll be required to have a water cooler, too. With this type of torch, the water cooler cools your TIG torch. You’ll find a radiator inside of the water cooler, just as you would in a car, that passes water through it, and a fan blows into it to help cool down the water.
If you can afford it, we’d highly recommend getting the water-cooled TIG torch with a water cooler. You’ll wind up saving money over time because the product is more efficient, and you’ll also be able to weld for more extended periods without stopping.
Now that you understand your options in TIG torches, we’ll cover the TIG welding machine set-up for welding mild steel.
TIG Welding Machine Set-Up for Mild Steel
You’ll discover two main settings when you start setting up your TIG welding machine for mild steel. Those two settings include gas flow and amperage. You’ll likely vary your amperage settings based on how thick the metal you plan to weld appears. You’ll want to set the amperage to a comfortable area and see how fast it melts the metal into your welding. You can adjust it as you see fit, but you might want to play around at first to figure out where you want the amperage to be before you get started on your mild steel welding project.
On the other hand, you’ll also need to set the gas flow rate. You’ll need to vary the gas flow rate up now and then based on your cup size, draft conditions, and how you are welding. If you have a larger cup and you’re working when it’s windy, you can use a gas rate between 5 CFH to 60 CFH. When you are welding mild steel and picking a gas to weld with, the gas you’ll most likely always use is pure Argon.
Below we’ve included a list that has guidelines for your machine set-up when welding mild steel.
1/16 Tungsten means you’ll need amps between 50-100, cup sizes of 4, 5, or 6, and a gas flow rate of 5-15 CFH.
3/32 Tungsten means you’ll need amps between 80-130, cup sizes of 6, 7, or 8, and a gas flow rate of 8-20 CFH.
1/8 Tungsten means you’ll need an amperage rate between 90 to 250, cup sizes of 6, 7, or 8, and a gas flow rate of 8 to 25 CFH.
TIG Welding Mild Steel
When TIG welding mild steel, you’ll want to use a DCEN (direct current electrode negative) polarity, Argon gas, and Thorium Tungsten. You’ll need to keep in mind when you weld any steel that you’ll have to shape the Tungsten to a fine point.
Welding steel is very similar to welding other types of materials. However, it does typically take people longer to learn how to weld steel, so expect there to be some practice time for experimentation as you are learning how to do this. The one thing that is very different about welding steel is the amount of good gas coverage you’ll need.
Sometimes when you are welding steel, you need to put your weld in an Argon bath or purge it with a filler gas, which is something different you’ll need to learn, and you’ll need to take some practice time out to do it. Not only that, but many people require more time to learn how to weld steel because steel has a bad habit of warping when too much heat is applied. When that happens, welds won’t brace and hold correctly, and you’ll wind up with distorted metal.
Now, if you run into some distortion while welding mild steel, you can control that by staggering your welds and bracing your weld area as often as possible.
Sanding Disk for Cleaning Mild Steel
Keep in mind that joint preparation is an essential part of TIG welding with mild steel. You’ll need to make sure the joint is very clean before you start your weld. If you don’t do this correctly, you’ll notice the filler wire isn’t flowing right into the joint. When you are welding on a mild steel joint that isn’t clean, the filler wire won’t stick totally to all of the areas of the joint. Since you’ll want to avoid doing this, make sure you hit the joint with a sanding disk or file to keep it clean.
Final Thoughts
Now that we’ve covered pretty much everything you’ll need to know about your TIG torch and TIG welder when it comes to welding mild steel, we hope you feel a lot more confident in approaching your welds. We helped you understand how to set up a TIG welder for mild steel, we covered how TIG welding works on mild steel, the TIG power supplies you’ll need, the TIG torch options for welding mild steel, how to set-up your electrode for mild steel, and how you’ll set-up your TIG welding machine for mild steel.
Remember, when it comes to TIG welding with mild steel, practice does make perfect. You’re going to need to retain plenty of your patience while you are learning to TIG weld. Since TIG welding requires you to use two hands, it’s a more laborious process to learn. Also, TIG welding with steel typically requires a little more time, effort, and experimentation to master. So, don’t be disappointed if you’re noticing that learning how to TIG weld is becoming an investment of time.
As long as you are enjoying learning how to TIG weld, and you’re getting there, you don’t have much to worry about as you progress. You’ll get there soon enough. So, get out there and experiment today!
Whether it is for general repairs, or creative projects around the house, having a welding machine in the home workshop can enable any DIY enthusiast to complete several additional home projects. To fuse metal, you’ll need a good welding machine, but don’t forget a welding apron, welding gloves, and eye protection.
Compared to traditional welders, welders designed for home use (whether a MIG welder, TIG welder, or stick welder) are relatively inexpensive and can tackle various small welding jobs. MIG and TIG welders as well as stick or flux-cored welders are the most common welders used for home use, and most can be powered by a 115V AC power source.
Here is a list of the best welders for home use, followed by a buying guide to help you select the best welder for your needs.
FC-120 120 AMP Flux Core Gasless Welder, is your go-to solution for all your welding needs. Whether you’re a DIY enthusiast or a professional welder, this welder offers exceptional performance, versatility, and ease of use. With a power output of 120 AMP MIG welder, this welder provides ample welding power to tackle a wide range of projects. From automotive repairs to fabrication tasks, this welder delivers precise and reliable welds, ensuring strong and durable connections. Equipped with a flux core welding feature, this welder eliminates the need for external shielding gas, making it incredibly convenient and cost-effective. The flux core wire creates its shielding gas when heated, providing excellent weld penetration and reducing the risk of weld defects.
Features:
1. Multi-function: Gasless flux cored wire welding and MMA.
2. Compact design, lightweight, but robust.
3. User-friendly and cost-effective.
4. Internal wire feeder, gear driven, support 1kg wire feeding.
5. Centralized control adapts to all kinds of air-free self-protecting wire less than 1.0 mm.
6. Equipped with a trimmer potentiometer on the control panel,it is more convenient for the voltage compensation of welding to make the welding effect more perfect.
7. MMA supports covered electrode welding with a maximum diameter of 3.2mm, with stable output current and continuous arc during welding.
8. Overheat, overcurrent, and overvoltage protection.
“Excellent machine,” wrote one happy customer. “I have had time to put this machine through its paces and can only say that it is everything it is supposed to be and then some! I use it on the job, on the small family farm, and at home. It is very portable, easy to set up and break down for storage when not in use.”
2. Best Home Welder for Small Jobs—120A Flux Core Welder
FC-120F 120 AMP Flux Core Gasless Welder, is your go-to solution for all your welding needs. Whether you’re a DIY enthusiast or a professional welder, this welder offers exceptional performance, versatility, and ease of use. With a power output of 120 AMP MIG welder, this welder provides ample welding power to tackle a wide range of projects. From automotive repairs to fabrication tasks, this welder delivers precise and reliable welds, ensuring strong and durable connections. Equipped with a flux core welding feature, this welder eliminates the need for external shielding gas, making it incredibly convenient and cost-effective. The flux core wire creates its own shielding gas when heated, providing excellent weld penetration and reducing the risk of weld defects.
Features:
1. Multi-function: Gasless flux cored wire welding and MMA.
2. Compact design, lightweight, but robust.
3. User-friendly and cost-effective.
4. Internal wire feeder, gear driven, support 1kg wire feeding.
5. Centralized control adapts to all kinds of air-free self-protecting wire less than 1.0 mm.
6. Equipped with a trimmer potentiometer on the control panel,it is more convenient for the voltage compensation of welding to make the welding effect more perfect.
7. MMA supports covered electrode welding with a maximum diameter of 3.2mm, with stable output current and continuous arc during welding.
8. Overheat, overcurrent, and overvoltage protection.
“I haven’t done any welding since high school and this was very easy to set up and use,” wrote one happy reviewer. “It’s light and very portable,” they added. “I’d recommend this as a first-time welder’s or a DIY homeowner’s starting machine any day.”
3. Best MIG Welder for Home Use— 140-Amp MIG Welder
The MIG-140 MIG Welder is a versatile welder that supports both gasless flux cored welding, and also welding that requires shielding gas, or gas welding. Since both welding methods are supported, this machine is ideal for both thin metals as well as for deep penetration on thick steel.
➠【 Master Multifunctional Welding 】 Experience the convenience of multi-process welding with the MIG-140. From MIG/MAG and LIFT TIG to MMA and FLUX CORED Wire welding, this welder is your all-in-one solution for a wide range of welding techniques.
➠【 Capable of Handling 1KG/5KG Wire Spools 】 Versatility at your fingertips! The MIG-140 can accommodate both 1KG and 5KG wire spools, giving you the freedom to choose the perfect fit for your welding tasks.
➠【 Stable Arc with Minimal Spatter 】 Achieve pristine welds with a stable arc and minimal spatter. The MIG-140 ensures superior welding performance, delivering clean and precise results every time.
➠【 Ideal for Both Outdoor and Indoor Use 】 From outdoor projects to indoor welding tasks, the MIG-140 is built to excel in any environment. Experience welding excellence, no matter where your work takes you.
“Highly recommended,” wrote one reviewer. “It comes with two spools (two pounds) and everything, besides gas tank, gas, and mask/gloves that you need to rock and roll. It’s simple to use and was built with quality. Plugs right into your 110V home outlets as well, no custom huge plugs like my stick welder has.”
4. Best For TIG and Stick Welding—TIG-200 AC DC Tig/Stick Welder
200 Amp AC/DC TIG Welder with Dual Voltage Technology
The TIG-200 AC/DC TIG Welder is an IGBT 200 Amp AC/DC TIG stick welder capable of welding on both 110-Volt and 220-Volt power. This tig welding machine unit’s portability allows for easy unit relocation and welding on the go, designed for aluminum fabrication, process piping, or critical maintenance work. With this arc welder, you will be able to weld thick material and thin material and save your favorite settings on the welder’s internal memory.
Features:
1. Multi-function welding-AC TIG, AC pulsed TIG, DC TIG, DC pulsed TIG, MMA, and auto welding
2. High-frequency arc starts with a high success rate
3. Memory function for easy operation,10 sets of parameters can be saved. 4. Adjustable clean width and clean scope
5. Optional torch with amperage control & optional foot pedal switch
6. Digital control technology and one-knob intelligent control panel
7. Intelligent over-voltage, low-voltage,over-current and over-heat protection, safe and reliable
8. Capable of different shapes of welding, like butt-joint, corner joint, T-joint,lap-joint and cruciform joint
“This machine is awesome!” wrote one satisfied reviewer. “After dialing in good settings, which was very easy and really effortless, I was able to lay down some decent beads right from the start. The HF start on this machine is incredible, smooth start, on-demand with foot pedal, and stable arc cannot be beaten by machines that cost three or four times as much.”
Choosing the Best Welder For Home Use—Buying Guide
It can be confusing when it comes to choosing the best welder for home use as there are a lot of specifications to sieve through, and special terminology that not all will be familiar with, especially those who are not professional welders.
This brief guide will look at some of the important things to consider when buying a welder.
TIG Welding/MIG Welding
MIG (metal inert gas) welding and TIG welding are welding processes that both require the use of gas to work. MIG welders are usually preferred by hobbyists or DIYers as MIG welding is one of the easiest welding processes to learn.
TIG welding on the other hand requires a little more skill but it produces the cleanest welds. Both MIG and TIG welding do not produce slag which is another plus to consider with both welding processes.
Flux Cored Arc Welding/Stick Welding
Stick welders and flux core welders, on the other hand, do not require gas to run and therefore produce slag during the welding process.
Stick welding is popular as it is fast and cheaper to run, however, the welding takes a little getting used to as an arc has to be maintained while the rod is burning. Flux-cored welding is slightly easier but is suitable mainly for ferrous metals and is not great for thinner metals.
Our next-generation TIG 200PI AC/DC TIG welder has taken all the best parts of the previous machine, including complete AC and DC TIG weld cycles, a high-frequency start and foot control compatibility, and improved on them. On top of all that, this machine now includes several new features to further enhance your welding experience.
LED Screen Visual Interface The most apparent change to this machine is the brand-new, upgraded interface. It now comes with a large LED Screen Visual Interface. The clear colour screen is bright and easy to read, so navigating the screen and settings is much easier, especially in dark work environments and low light conditions.
AC Waveforms You can now adjust your AC waveform on top of your AC frequency and balance. Completely customise your aluminium welds by switching between Sine, Square and Triangle waves to change the arc characteristics, bead profile and penetration to suit your needs.
Mixed AC/DC Get the best of both worlds with the addition of Mixed AC/DC. Mixed AC/DC welding combines TIG AC and TIG DC negative in the one weld.
There are two periods during a mixed weld. The first is the AC period, where the oxide film is broken, and surface impurities are flushed out. The second, the DC negative period, is where the arc becomes narrower and penetrative, with higher heat inputs.
There are quite a few benefits from this type of welding, including higher welding speeds and penetration, so you can weld on thicker materials and get a faster weld puddle on cold workpieces.
Advanced MMA Features As both a TIG and stick welder, our new TIG-200PI AC DC TIG WELDER now comes with a range of advanced MMA features as well.
We’ve added an adjustable hot start designed to help with striking an arc. The hot start temporarily boosts the output current at the start, making striking an arc, even with difficult electrodes, much easier. You get smoother arc starts, improving the quality of your weld.
We’ve also added adjustable arc force, which adjusts the current (and, therefore, the heat) based on the length of the arc. When the arc becomes shorter, the current increases to keep it stable and stop the electrode from sticking. When the arc becomes longer, the current will decrease. The level of this response is what’s adjustable on the machine.
The adjustable arc force allows you to fine-tune your arc and improve your weld’s quality and consistency, especially in tight corners or when welding overhead or vertically.
The machine also now comes with built-in anti-stick, a feature that’s designed to keep you from ever sticking an electrode again, whether you’re at the start of a weld, halfway through or about to end one.
High-Speed Air-Forced Cooling Fan
We’ve introduced an improved cooling system in these machines, and the new smart fan only turns on when the machine needs it, diminishing the noise in your work environment. It also reduces the number of contaminants and dust that get pulled into these machines, increasing the reliability and durability of them.