TIG Welding Calculator
Estimate TIG amperage, tungsten size, filler rod, cup size, shielding gas, travel speed, pulse heat factor, and heat input from material thickness and joint setup.
| Tungsten size | DCEN range | AC range | Typical use |
|---|---|---|---|
| 0.040 in / 1.0 mm | 5-60 A | 5-45 A | Thin sheet, small autogenous welds, fine arc starts |
| 1/16 in / 1.6 mm | 20-100 A | 20-80 A | Sheet, tube, light stainless, thin aluminum |
| 3/32 in / 2.4 mm | 80-180 A | 70-150 A | General shop TIG, plate edges, aluminum sheet |
| 1/8 in / 3.2 mm | 150-250 A | 120-220 A | Heavier plate, aluminum sections, higher heat work |
| 5/32 in / 4.0 mm | 220-320 A | 180-300 A | High amperage AC, thick aluminum, copper heat sink work |
| Thickness | Filler diameter | Cup size | Argon flow |
|---|---|---|---|
| 0.020-0.050 in | 0.035 or 0.045 in | #4-#5 | 8-14 CFH with short stickout |
| 0.060-0.090 in | 1/16 in | #5-#7 | 12-18 CFH for most bench work |
| 0.100-0.160 in | 1/16 or 3/32 in | #6-#8 | 15-22 CFH, trim for turbulence |
| 0.180-0.250 in | 3/32 or 1/8 in | #7-#10 | 18-28 CFH or more for large lenses |
| Over 0.250 in | 1/8 in and multi-pass | #8-#12 | 22-35 CFH with torch angle control |
| Pulse factor | Travel change | Best fit | Setup note |
|---|---|---|---|
| 100% | Base speed | Steady DC or AC | Use when puddle control is easy and heat input is acceptable |
| 85-95% | Slightly slower | Sheet or tube | Good for rhythm, dab timing, and edge control |
| 70-84% | Moderate slower | Stainless roots | Reduces average heat but may need more peak amperage |
| 55-69% | Slow detail work | Thin stainless | Watch lack of fusion if peak time is too short |
| 35-54% | Special control | Very thin metal | Procedure development and test coupons are essential |
There are many differenty settings for TIG welding processes, and the settings have to be matched to the metal being welded. TIG welding involve many different variables, so a TIG welding calculator can help the welder to properly set the parameter for the welding process. The TIG welding calculator make it so that the welder doesnt have to guess at the various settings for the weld, and allows the welder to focus upon the weld being performed rather than upon the mathematics that must be performed to determine those settings.
The variable for TIG welding involve each of the other variables for the welding process. For instance, the thickness of the metal will impact the amperage settings for the weld; however, other variables, such as the type of joint that the metal is forming or the position of the metal relative to the welder can impact the amperage requirements for the weld by fifteen or twenty percent. Metals that are to be welded in a fillet weld will require different amperage settings than metals welded in a flat butt joint, but metals welded in an overhead position will require less current than metals welded in a flat joint.
How a TIG Welding Calculator Helps Welders
The TIG welding calculator performs these calculations so that the welder does not have to memorize these settings and calculate them in there minds while welding. The size of the tungsten that is to be utilized in the welding process is based off the amperage settings that are selected. If the amperage settings is high, a small tungsten may overheat; however, if the amperage settings are low, a large tungsten can make it more harder to start the weld.
The TIG welding calculator helps to suggest the size of tungsten that is to be utilized based upon the amperage settings and the metals polarity, providing the welder a starting point for adjusting the tungsten size to optimize the welding process. The gas flow and cup size for the welding process are also related to each other; the gas flow is used to protect the weld from the atmosphere. Using too low of a gas flow can expose the weld to oxygen and nitrogen in the atmosphere; using too high a flow rate of welding gas can create turbulence in the weld that can also expose the weld to atmospheric gases.
The TIG welding calculator models the gas flow that is to be utilized based upon the size of the cup and the metal that is to be welded, allowing the welder to compare the two and make any necessary adjustment to the gas flow settings. The travel speed and the pulse settings for TIG welding impact the amount of heat that is input into the weld. Heat input into metals like stainless steel and titanium is more restrictive than metals like thick aluminum.
Furthermore, excessive heat can alter the property of the metal or distort the metal. The TIG welding calculator allows the welder to see the heat input for the metal based upon the pulse factor for the weld, allowing the welder to adjust the travel speed of the metal to maintain an even and appropriate amount of heat input. The heat input of the weld is another importantly measurement to understand for the welder.
Most welders understand that one rule for TIG welding can be applied universally to all metals; the rule is that one amp is used for every thousandth of an inch of thickness in the metal. However, this rule is primarily applied to mild steel. Metals like aluminum and copper require more amperage to weld than mild steel, while metals like stainless and titanium require less amperage than mild steel.
These considerations are built into the TIG welding calculator to assist the welder in understanding that these metals require different current settings than mild steel. Most welders understand that metals may be perfect in thickness and in joint type, but there are many issues with the weld metals in real world situations. Drafts from doors, the base metal may be cold, and it is possible that weld metals contain oxide on their surfaces.
The TIG welding calculator includes an allowance for these variables as well. An increased amperage is calculated for the weld to account for these more difficult welding situations. Tables exist that list the various size of tungsten that are typically used for metals of different thicknesses.
These tables are not meant to replace the TIG welding calculator, but instead provide the welder with additional context for understanding the settings that the TIG welding calculator calculates. The welder can utilize the table to understand if the settings calculated by the TIG welding calculator are in fact meaningful for their welding situations. Another factor into TIG welding is the use of pulse welding.
For metals like thin stainless steel, a lower pulse factor will reduce the amount of heat that is emit by the metal. Reducing the amount of heat that is input into thin metals helps to avoid metal distortion. However, using a lower pulse factor will require the welder to lower their travel speed to allow for adequate fusion between the metals.
The TIG welding calculator will calculate both the amperage and heat input for these settings to allow the welder to understand if adjusting the travel speed of the metal will bring acceptable results to the welding task. One thing that the TIG welding calculator will not do is replace the need for testing the weld parameters. The settings calculated by the TIG welding calculator are merely a starting point; the welder will still have to make adjustment to those settings while welding is occurring.
Using a TIG welding calculator will help to eliminate one of the frustration for the welder as it provides a calculated starting point for the welding parameters as opposed to a guessed starting point. Furthermore, understanding how each variable impact the other variables will allow for welders to better understand which settings to adjust during the welding process prior to striking the welding arc.
