Welding filler metals mastery for TIG welders

Selecting the wrong rod is the fastest way to invite porosity, cracking, color mismatch, and failed inspections. TIG Welding Secrets gives you a precise, field-tested system for choosing and using welding filler metals so your first pass is the best pass—every alloy, every position, every code. Decode AWS classifications at a glance, match filler to base metal, service environment, and procedure, and lock in predictable wetting, bead profile, and mechanicals without trial-and-error.

Built by CWIs and aerospace TIG leads, this guide translates metallurgy into practical moves at the torch. Get clear comparisons—ER70S-2 vs -6, 308L vs 309L vs 312, 4043 vs 5356, nickel and CuNi choices—plus dilution limits, ferrite number targets for stainless, and how to handle dissimilar joints (e.g., 304 to carbon). Nail purge discipline for stainless and titanium, control heat input and interpass, and manage oxide removal so X-ray quality isn’t a coin toss. You’ll cut rework, pass NDT with confidence, and deliver welds that stay sound in real service—pressure, vibration, corrosion, and heat.

• Fast filler selection using a compatibility matrix and flowchart tied to AWS/ASME requirements.
• Defect fixes that stick: hot cracking, porosity, lack of fusion, sugar, color mismatch on aluminum.
• Exact parameters that matter: amperage windows, travel speed, gas purity/flow, arc length, torch angle, and wire prep/storage.