TIG (GTAW)

TIG (GTAW) creates precise, high‑quality fusion welds with excellent control of heat input, ideal for thin sections, critical joints, and hard‑to‑weld alloys.

Overview

TIG (GTAW) welding uses a non-consumable tungsten electrode and a separate filler rod to produce clean, high-quality welds under an inert gas shield. The process gives the operator fine control over heat input and filler addition, which is critical for thin material, visible welds, and reactive alloys like aluminum and titanium. TIG can be run manually or automated, and is common in applications where weld appearance, precision, and metallurgical quality matter.

You should consider TIG when you need small, controlled weld beads, minimal spatter, and low distortion on thin-gauge or high-value parts. It excels on stainless, aluminum, and specialty alloys, but is slower and more labor-intensive than wire-fed processes, which raises cost for long weld lengths or high production volumes. Joints must be well-prepped and fixtured, and operators need skill to maintain consistency. TIG is often the process of choice for prototype work, low to medium volumes, and safety-critical welds where inspection and certification are required.

Common Materials

  • Stainless steel 304
  • Aluminum 6061
  • Carbon steel A36
  • Titanium Grade 5
  • Inconel 625
  • Stainless steel 316

Tolerances

±0.030" on weld size and location with good fixturing; overall assembly distortion control depends strongly on joint design and sequence

Applications

  • Stainless food-grade tanks and piping
  • Aluminum bicycle frames
  • Aerospace hydraulic and fuel lines
  • Titanium exhaust and intake components
  • Sanitary process piping welds
  • Instrumentation and vacuum chambers

When to Choose TIG (GTAW)

Choose TIG (GTAW) when weld appearance, precision, or metallurgy are more important than deposition rate. It fits thin sections, small welds, dissimilar or specialty alloys, and joints that need excellent control of heat input. It suits prototypes, repair work, and low-to-medium production where setup time and operator skill are justified by weld quality.

vs MIG (GMAW)

Pick TIG over MIG when you need superior bead appearance, precise heat control, or are welding thin-gauge material and specialty alloys like titanium or Inconel. TIG is slower but gives cleaner starts, no spatter, and better control of penetration for critical or cosmetic welds.

vs Stick (SMAW)

Choose TIG instead of Stick when you need clean, low-spatter welds and tight control over heat input, especially on thin or high-alloy materials. TIG is better for shop or controlled environments where weld appearance, precision, and lower post-weld cleanup justify slower travel speed.

vs Resistance Welding

Use TIG instead of resistance welding when you have non-overlap joints, varying thicknesses, or need full-penetration welds rather than spot or seam welds. TIG suits lower volumes, complex geometries, and applications where access for electrodes or high clamping forces is impractical.

vs Laser Welding

Select TIG instead of laser welding when you can tolerate slightly larger heat-affected zones and want lower equipment cost and easier setup. TIG is more forgiving on joint fit-up and surface condition, and suits shops that don’t need ultra-high speed or micron-level precision.

vs Brazing & Soldering

Use TIG over brazing or soldering when you need full fusion joints with higher strength and temperature capability. TIG is appropriate where joint loads are structural, environments are hot, or long-term creep or joint fatigue are concerns.

Design Considerations

  • Specify joint type, weld size, and length clearly on drawings using standard weld symbols to avoid over-welding and excess cost
  • Design joints for tight, consistent fit-up; large gaps increase heat input, distortion, and filler usage
  • Provide clear torch and filler access with at least one inch of straight approach and room for gas cup and hand movement
  • Avoid unnecessary multi-pass welds by using realistic weld sizes matched to loads instead of conservative oversizing
  • Limit abrupt thickness transitions; use tapers or chamfers to reduce restraint and distortion in welded areas
  • Call out any required back-purging for stainless or titanium and define acceptable discoloration level so shops can plan fixturing and gas usage