There are a lot of options to consider when buying your first TIG welder, as well as many different machines and available features to choose from, so how do you know what machine to buy?
To get started on the path to the machine that's right for you, let's first talk about what TIG welding is. TIG stands for Tungsten Inert Gas Welding (more formally referred to as GTAW or Gas Tungsten Arc Welding) and it utilizes a piece of Tungsten inside a torch to create an arc of electrical current between the tungsten and the base metal, heating the base metal to it's melting point and allowing for the addition of filler metal. To keep this liquified metal from being contaminated by the oxygen in the air, the TIG torch pushes Argon gas into the weld puddle, which allows the puddle time to cool before oxygen can contaminate it. This TIG torch arc is moved across the entirety of the weld joint while adding filler metal in order to join the two work pieces together securely. Different thicknesses of metal will require different amperages (the thicker the metal the more amps required to weld it) so you'll see a variety of different amperage ratings when you begin looking for your first machine.
That's obviously a very simple overview of what the TIG welding process is, but it's enough to give you the basic concept to understand some of the basic features you'll see in a machine. From here we will dive a little deeper into some of the most commonly discussed features and how important those features are likely to be for you. I'll start by breaking this out into a few (admittedly simplified) categories of user so you can select the one which most closely applies to you. At the end of each category, I'll list a few machines that I feel would be suitable for that type of user.
HOBBYIST (home projects and light duty fab work for yourself)
SIDE HUSTLE (light duty work for yourself and occasional customers)
FULL TIME (fabrication for customers is your main source of income)
HOBBYIST
For the hobbyist, or someone just dipping their toe into fabrication for the first time, the level of project being undertaken is going to be fairly simple as you begin building your skills in the process of TIG welding. As a result, some of the more complex features found on high dollar machines aren't likely to be quite as important as practice time with your new machine. However, there are a few you'll want to look for.
160 Amps or More: While many of the projects I work on (gas tanks, fenders, oil tanks) are welded at amperages of 80 or below, there are times when you'll want to add a beefy mount somewhere or join two pieces of thicker metal for a particular project. For this reason, I recommend a machine that has at least 160 amps, though 200 would be better. Also keep in mind that many modern inverter machines run on 110v (standard household outlet) as well as 220v (dryer plug style outlet) and the advertised amperage of the machine can only be reached using that 220v plug. Something to be aware of if you don't have a space with access to 220v power.
Remote Capable: One of the biggest benefits of TIG welding is the ability to change the amperage on the fly through use of a foot pedal or torch mounted amperage controller. This allows you to ramp up the amps to get a puddle going but also to back off the amps if things start getting a little too hot. You'll want to make sure whichever machine you buy is capable of utilizing a remote amperage controller to make your life easier
Dual Voltage: Whether you're only interested in doing small projects in your garage or have aspirations of taking your welding to the next level and starting a side hustle, the ability to plug your machine into a standard household outlet or a 220v plug is important. Dual voltage machines are extremely common today and give you the opportunity to grow into the machine in the future in the event that you're currently limited to 110v power but want a machine that can run on 220v in the future when that power source becomes available.
Internal Gas Solenoid: This is a standard feature on most machines but is something you want to confirm before pulling the trigger on your first TIG machine. As we discussed earlier, TIG welding requires Argon gas to protect the weld puddle from oxygen. Internal gas solenoids automatically initiate the flow of Argon when you start your weld, whereas some older machines have a manual valve on the torch that you have to remember to open before you start welding (and close when you finish...or your argon will continue to flow until the bottle is empty). Because the argon flow is very quiet, it's incredibly easy to forget to turn the valve off after you've finished your weld, and with so many affordable machines out there with internal gas solenoids, I would consider this a mandatory feature for a new TIG welder.
Recommendations for the Hobbyist
SIDE HUSTLE
Once you've decided you're ready to take your welding to the next level and start a side hustle, you'll likely have been welding for quite some time or at least have had a lot of practice time under your belt. At this point in your welding career, some of the seemingly minor features that are often overlooked can really make or break your experience with a machine. Here's a few of the underappreciated features you'll want to make sure you're paying attention to when considering a machine for your side hustle. (Side note: All of these features carry over into full time as well)
Adjustable Postflow: This feature lets you set the time (in seconds) that the argon gas continues to flow from your TIG torch after you finish the weld. It may not seem like an important feature at first, but you can't weld without Argon, and when you're cranking out side hustle work on a Sunday when all the welding shops are closed and you're trying to finish a project without only a tiny bit of gas left in your bottle, being able to turn down the post flow can really save your session.
Alternating Current (AC): No, we're not talking about keeping your shop cool in the summertime. Alternating Current, abbreviated as AC, is required for welding on aluminum. While the average hobbyist may not have a need to weld aluminum, once you've started your side hustle, the ability to take on aluminum jobs can be the difference between a customer using your services or moving on to the next guy. Alternating current machines typically allow you to adjust the current frequency (in Hz) and the current balance (measured in percent of time spent on positive or negative current). We will get into detail on dialing in these settings in a future blog post but to keep things simple, be sure to look for a machine that does AC and DC.
High Frequency Start: This is one of those items that isn't absolutely necessary for all welding applications, but can certainly make your life a lot easier when you have it, especially for projects with a lot of tack welding required. High Frequency start allows the arc to jump from your tungsten to the work piece at the press of a button (or foot pedal) without requiring you to touch and lift your tungsten like with Lift Arc. This can also help to keep your tungsten sharp and avoid contamination with the base metal.
Pulse: I'll be honest with you, I debated on whether or not to include this feature in our list. Here's why...what pulse does is allow you to set the machine to automatically alternate between a high amperage and a low amperage. This automated pulsing between high and low can create a very uniform-looking weld with the "stack of dimes" appearance that we all love. However, while it certainly shines in situations like outside corner joints where you won't be using filler metal, it's not absolutely necessary. That being said, when thinking back to a few trailer fender jobs I did that involved ten linear feet of outside corner welds per fender, I was certainly happy to have it. All of the machines I've listed below have this feature, and it's becoming a standard on many machines today, so for that reason I've included it here.
Recommendations for a SIDE HUSTLE
AHP ALPHATIG 201XD (This is the machine I started Ferro Fabrication with and still use today)
FULL TIME
As mentioned above, the recommendations laid out for features to look for in a side hustle machine all apply to those looking to go full time with their businesses. Chances are that if you've been running a side hustle successfully and are ready to go full time, you already know what features you think are most important in a machine and aren't looking for recommendations. That being said, I'll list my thoughts here as a road map for someone reading this who may be looking to purchase one machine only, with the mentality of "buy once, cry once", and is doing so with the intention of going full time in the future.
Duty Cycle: This is a big one. To put it in simple terms, duty cycle (which is expressed as a percentage) represents the amount of time the machine can run at a given amperage before overheating. To give an example, a machine with a 30% duty cycle at 200 amps could run for 3 out of 10 minutes at that setting, and would need 7 minutes to cool. As a hobbyist or someone with a side hustle, you may never need to think about duty cycle. But when going full time, if you're running a batch of part that requires consistent arc time day in and day out, it may come into play.
AC Frequency/Balance: Like we discussed in the side hustle section, full time welders will absolutely want the ability to weld aluminum which requires AC. Additionally, you'll also want a machine which allows you to adjust the AC frequency and the AC balance, to better tailor the machine to the job at hand. Back in the days when transformer-based machines ruled the roost, these features were but a dream, today however, we can expect to see them from all manufacturers.
Water Cooler Compatible: In going full time and searching for a machine with a high duty cycle which will allow you to weld for long periods of time without overheating the machine, you'll also want to consider a machine which can accept a water cooled torch. A water cooled torch connects to a water cooler which pumps...you guessed it...cool water, into the torch head to keep it from getting too hot to hold. A water cooler is absolutely essential for those looking to weld for hours on end without stopping for breaks. Many companies make their own water coolers and some third party companies produce them to fit common models. All recommendations for welders in this category are water cooler capable.
Proven Warranty: This is something that's worth discussing once you're talking about a full time business. With newer brands like Everlast and AHP becoming big players in the welding game, one of the biggest reasons why someone might choose a legacy brand like Miller or Lincoln are for the availability of parts and the proven nature of their warranty programs. Most local welding shops either are or can point you to a service center for Millers and Lincolns whereas an AHP or Everlast will likely need to be shipped back to the manufacturer on your own dime. This may never come up and your machine may never need warranty work, but it's something people ought to consider if that welder being operational is what's keeping food on your table.
Recommendations for FULL TIME
Note: There are many welders out there which can be used for full time work, but for the reasons I listed above I've kept these recommendations to two which have industry-leading 60% duty cycles at max amperage, and both of which I've either used personally as a full time welder or have had recommended by someone also using one full time. If you'd like to submit an addition to this list, drop me a line in the comments section.
That about wraps it up for what to look for in your first TIG welder, if you've got any additional questions feel free to reach out and we can talk in more details about your specific situation.
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