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.

• Top 5 TIG Welder Reviews UK
• Top 3 HITBOX TIG Welder Reviews UK

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.