TIG Welding Calculator — Settings by Material & Thickness | Welders Supply — Welding Guides, Reviews & Technical Reference

Q: "How do I know what amperage to use for TIG welding?"

"The baseline rule is 1 amp per 0.001 inch of material thickness for steel and stainless. Aluminum needs about 25% more amperage because AC is less efficient than DCEN. Start at the low end of the range shown and increase until you get a fluid puddle that moves smoothly without overheating the base metal."

Q: "What tungsten should I use for TIG welding?"

"2% lanthanated (blue band) works for steel, stainless, chromoly, and titanium on DCEN. For aluminum on AC, use 2% ceriated (grey band) or pure tungsten (green band). Lanthanated tungsten is the most versatile — if you only buy one type, make it lanthanated."

Q: "Do TIG settings change for different joint types?"

"Yes. Butt joints use baseline amperage. Lap and T-joints need about 10% more amperage because the heat sinks into two pieces at the joint. Pipe joints require reducing amperage 10-15% for the overhead section of the rotation. The calculator adjusts for these differences automatically."

Select your material, thickness, and joint type. The calculator returns tungsten type and size, filler rod, cup size, amperage range, shielding gas, current type, and pulse recommendations.

All settings assume clean material and flat position. For vertical and overhead TIG welding, reduce amperage 10-15% from the values shown.

Select your parameters above and click Calculate.

How to Use These Settings

Set your machine to the current type shown (DCEN for steel, stainless, chromoly, and titanium; AC for aluminum). This is non-negotiable — the wrong polarity will destroy your tungsten or fail to clean the oxide layer.
Set amperage to the middle of the recommended range. Use your foot pedal or finger control to modulate — start at about 75% and increase until the puddle flows smoothly.
Sharpen your tungsten to a point for DCEN work (steel, stainless). For AC aluminum, the tip will ball slightly — that is normal. Grind longitudinally, never across the tip.
Set gas flow on your flowmeter to the recommended CFH. More is not better — excessive flow creates turbulence and actually reduces shielding effectiveness.
Cup size determines gas coverage area. Use the recommended size as a starting point. Switch to a gas lens if you need longer tungsten extension for tight access.

For the complete TIG welding reference, see the TIG welding section. For filler rod selection details, see the filler metal guide.

Frequently Asked Questions

How do I know what amperage to use for TIG welding?

The baseline rule is 1 amp per 0.001 inch of material thickness for steel and stainless. Aluminum needs about 25% more amperage because AC is less efficient than DCEN. Start at the low end of the range shown and increase until you get a fluid puddle that moves smoothly without overheating the base metal.

What tungsten should I use for TIG welding?

2% lanthanated (blue band) works for steel, stainless, chromoly, and titanium on DCEN. For aluminum on AC, use 2% ceriated (grey band) or pure tungsten (green band). Lanthanated tungsten is the most versatile — if you only buy one type, make it lanthanated.

Do TIG settings change for different joint types?

Yes. Butt joints use baseline amperage. Lap and T-joints need about 10% more amperage because the heat sinks into two pieces at the joint. Pipe joints require reducing amperage 10-15% for the overhead section of the rotation. The calculator adjusts for these differences automatically.