Beyond the funny welder mug: TIG Welding Secrets for real shop results

A funny welder mug gets a laugh—precision TIG pays the bills. TIG Welding Secrets distills hard-won, shop-tested technique into a clear, repeatable system for cleaner beads, fewer grind-backs, and predictable heat control. Authored by an ASME Section IX–certified TIG specialist, it aligns with real WPS discipline: fit-up standards, torch posture, filler timing, and gas coverage that hold up on stainless, chromoly, and aluminum.

Expect practical, numbers-first guidance. For thin stainless (0.040–0.065 in): DCEN, 2% lanthanated 3/32 in sharpened 20–30°, #8 gas lens, 15–20 CFH, tight arc length, 0.045–1/16 in filler, staged tacks, and back purging to prevent sugaring. For 6061 aluminum: AC, 120 Hz, 70–75% EN, 3/32 in tungsten, 20–25 CFH, controlled travel to manage etch width and wet-in. Dial-in advice covers cup selection, gas lens use, pulse strategy, joint sequencing to limit distortion, and a rapid troubleshooting matrix for porosity, undercut, lack of fusion, and tungsten contamination. Welders move from “good enough” to repeatable, inspection-ready results while cutting rework time and consumable waste.

• Step-by-step procedures for fillets, butt joints, thin-wall tubing, and food-grade stainless with purge setups.
• Settings tables and WPS-style checklists that speed setup and standardize results across the team.
• Field-proven fixes for heat tint, crater cracking, arc wander, and inconsistent bead profile.