TIG Welding Settings Chart - Guide for Beginners

Getting the right settings is the key to successful TIG welding. If your settings are wrong, you’ll struggle with poor penetration, unstable arc, contamination, or messy welds — no matter how good your technique is.

This guide provides a complete TIG welding settings chart, along with detailed explanations to help you understand how to adjust your machine for different materials and thicknesses.

🔧 Why TIG Welding Settings Matter

TIG welding requires precise control over:

Amperage
Gas flow
Tungsten size
Arc length
Travel speed

👉 Even small changes can dramatically affect your weld quality.

📊 TIG Welding Settings Chart (Steel & Stainless – DC TIG)

🔥 General Rule:

1 amp per 0.001 inch thickness (approximate)

⚙️ Mild Steel / Stainless Steel Settings

Material Thickness	Amperage	Tungsten Size	Gas Flow
1mm	30–50A	1.6mm	6–8 L/min
2mm	50–80A	1.6–2.0mm	6–8 L/min
3mm	80–110A	2.4mm	7–9 L/min
4mm	100–130A	2.4mm	7–10 L/min
5mm	120–150A	2.4mm	8–10 L/min
6mm+	150–200A	2.4–3.2mm	8–12 L/min

👉 These settings are ideal for most UK home workshop TIG welding.

📊 TIG Welding Settings Chart (Aluminium – AC TIG)

⚙️ Aluminium Settings (AC TIG)

Thickness	Amperage	Tungsten	Gas Flow
1mm	40–70A	1.6mm	7–9 L/min
2mm	70–110A	2.4mm	8–10 L/min
3mm	100–140A	2.4mm	8–12 L/min
4mm+	140–200A	2.4–3.2mm	10–12 L/min

👉 Aluminium requires AC TIG due to oxide layer removal.

⚙️ Key TIG Welding Settings Explained

🔥 1. Amperage (Most Important Setting)

Controls heat input
Affects penetration and bead size

Tips:

Too low → poor penetration
Too high → burn-through

👉 Start mid-range and adjust as needed.

💨 2. Gas Flow Rate

Protects weld from contamination
Uses argon gas

Recommended:

6–10 L/min (steel)
8–12 L/min (aluminium)

👉 Too much gas can cause turbulence — not just too little.

🔩 3. Tungsten Size & Type

Tungsten Size	Amperage Range
1.0mm	10–70A
1.6mm	50–120A
2.4mm	100–200A
3.2mm	200A+

Tip:

DC TIG → sharp point
AC TIG → slightly rounded tip

⚡ 4. Polarity (Critical)

DC TIG → DCEN (Electrode Negative)
AC TIG → aluminium welding

👉 Wrong polarity = poor weld performance.

🔥 5. Arc Length

Ideal: 2–3mm
Too long → unstable arc
Too short → contamination

⚙️ 6. Travel Speed

Too fast → poor penetration
Too slow → wide weld

👉 Consistency is key.

🧠 How to Set Up Your TIG Welder (Step-by-Step)

Step 1: Select Material

Steel → DC TIG
Aluminium → AC TIG

Step 2: Set Amperage

Based on thickness chart above

Step 3: Adjust Gas Flow

Start around 7–8 L/min

Step 4: Choose Tungsten

Match size to amperage

Step 5: Test Weld

Adjust settings as needed

👉 Always test on scrap metal first.

⚖️ Common Setting Mistakes

❌ Too much amperage

✔ Causes burn-through

❌ Too little gas

✔ Leads to contamination

❌ Wrong tungsten size

✔ Affects arc stability

❌ Incorrect polarity

✔ Reduces performance

❌ Ignoring material thickness

✔ Causes poor results

🛠️ Pro Tips for Welders

Use inverter TIG welders for better control
Always weld in dry conditions (important in UK climate)
Keep gas cylinder secure and upright
Practise on scrap before real projects
Use HF start for easier ignition

📈 Beginner Setup Example

Welding 2mm Mild Steel:

Amperage: 60–70A
Tungsten: 1.6mm
Gas flow: 7 L/min
Polarity: DCEN

👉 This is a perfect beginner starting point.

❓ FAQs

What is the best TIG welding setting for beginners?

Start with mid-range amperage and adjust based on weld pool behaviour.

How much gas flow do I need?

Typically 6–10 L/min for steel.

What happens if amperage is too low?

Poor penetration and weak welds.

Do settings change with material?

Yes — aluminium requires AC TIG and different settings.

Final Thoughts

Using the correct TIG welding settings chart is essential for achieving clean, strong, and consistent welds.

👉 Focus on:

Correct amperage
Proper gas flow
Suitable tungsten
Stable technique

With practice and proper settings, your TIG welding will improve rapidly.

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