TIG Welding Settings Chart for Different Materials (Steel, Aluminum, Copper & Titanium)

TIG Welding Settings Chart for Different Materials is the quickest way to choose the correct amperage, tungsten size, filler rod, and shielding gas for steel, stainless steel, aluminum, copper, and titanium. Using the right settings helps produce cleaner welds, better penetration, and fewer welding defects.

Struggling to get clean TIG welds? If your tungsten keeps contaminating, your weld bead looks too wide, or you’re constantly burning through metal, there’s a good chance your settings are the problem—not your welding skills.

As a welding instructor, I’ve seen many beginners blame themselves when the real issue was incorrect amperage, wrong tungsten size, or improper gas flow. This guide includes a practical TIG welding settings chart for different materials so you can confidently set up your machine and achieve professional-looking welds.

What Are the Correct TIG Welding Settings?

The correct TIG welding settings depend on the material and thickness. Mild steel typically uses 40–120 amps with DCEN and 100% argon, while aluminum requires AC current and 80–220 amps. Choosing the right tungsten size, filler rod, and gas flow produces cleaner, stronger welds.

This guide provides a practical TIG welding settings chart for different materials so you can set up your machine correctly and start producing cleaner, stronger welds.

Quick TIG Welding Settings Chart

New to TIG welding? Start with our TIG Welding Guide for beginners: Complete step by step setup and Techniques and learn how to set up your machine, choose the right tungsten, and master basic torch control before dialing in advanced settings.

Why TIG Welding Settings Matter

TIG welding is one of the most precise welding processes, but it’s also the least forgiving. Small changes in settings can dramatically affect:

• Arc stability
• Penetration
• Weld appearance
• Distortion
• Tungsten life
• Overall weld quality

The good news? Once you understand the recommended settings, TIG welding becomes much easier.

Recommended TIG Gas Flow Rates

Shielding Gas Cup Size

Too much shielding gas can create turbulence and pull oxygen into the weld, leading to porosity and oxidation.

For additional technical specifications, download filler metal datasheets from the American Welding Society (AWS).

TIG Settings for Mild Steel

Current Type:

DCEN (Direct Current Electrode Negative)

Best For:

• Automotive repairs
• Structural fabrication
• General workshop projects

Pro Tip:

Keep a short arc length—about the diameter of your tungsten—to get a smooth and focused weld bead.

Best TIG Settings for Stainless Steel

Current Type:

DCEN

Common Mistake:

Many beginners use too much heat, causing discoloration and distortion.

Instructor Tip:

Use a lower amperage and move steadily to preserve corrosion resistance.

Recommended TIG Settings for Aluminum

Current Type:

AC with 65-75% electrode negative balance.

Why AC?

The cleaning action of AC removes the aluminum oxide layer that melts at a much higher temperature than the base metal.

AC Balance Settings for Aluminum

A beginner searching for TIG settings usually also wants:

Common Beginner Problem:

Burning through thin aluminum.

Solution:

• Use a foot pedal if possible.
• Start with lower amperage.
• Increase heat gradually.

TIG Welding Parameters for Copper

Copper absorbs heat rapidly, requiring much higher amperage than steel. Preheating copper above 6 mm thickness is highly recommended.

Tips:

• Preheat thick sections.
• Use larger tungsten.
• Consider an Argon-Helium mix for improved penetration.

TIG Settings for Titanium

Titanium is extremely sensitive to contamination. Titanium welds require trailing shields or gas lenses for optimal protection.

Important:

Even a small amount of oxygen can ruin the weld.

Best Practices:

• Use extra shielding.
• Keep everything perfectly clean.
• Avoid touching the tungsten to the weld puddle.

Choosing the Correct Tungsten Size

Tungsten Type Chart

Choosing Your First Machine

Looking for a welder that makes setup easier? Explore our Best TIG Welders for Beginners to find instructor-recommended machines for every budget.

7 TIG Settings Mistakes Beginners Make

• Using too much gas.
• Incorrect tungsten stick-out.
• Wrong polarity.
• Using contaminated tungsten.
• Excessive amperage.
• Incorrect filler rod.
• Holding a long arc.

Signs Your TIG Settings Are Wrong

Amperage Too Low

❌ Poor penetration
❌ Wandering arc
❌ High weld buildup

Amperage Too High

❌ Burn-through
❌ Excessive heat tint
❌ Tungsten contamination

Gas Flow Too Low

❌ Porosity
❌ Gray, dirty welds

Gas Flow Too High

❌ Turbulence
❌ Oxidized welds

Beginner’s Starting Formula

A simple rule I teach new welders:

1 amp per 0.001 inch of material thickness

Example:

• 1/8 inch steel (0.125″)
• Start around 125 amps and fine-tune from there.

Material Thickness and Amperage chart

Final Thoughts

Great TIG welding isn’t about buying an expensive machine—it’s about understanding your settings.

Frequently Asked Questions

Which material gives you the most trouble with TIG welding—steel, aluminum, or stainless? Drop your answer in the comments and I’ll help you dial in your settings.