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PWS ENGINEERING TOOLS

TIG Welding Settings App

Find a current reference, AC/DC setup, tungsten, filler and gas-flow guidance. Enter what you know. Optional fields can stay blank; assumptions are shown with the results.

1. Your metal and joint

Metal Thickness of thinner piece For tube: enter wall thickness, not outside dimensions. Thickness unit 1/8 inch = 0.125. Changing units converts an entered value. Joint Position Current control

2. Optional equipment details

Machine capability Filler alloy Metal type alone does not identify the alloy or required filler. Filler rod diameter Reference size is a starting guide, not a required weld size or qualified rod selection. Tungsten diameter Size guidance assumes oxide-added tungsten. A 2% lanthanated or ceriated electrode is a useful inverter reference; confirm the actual product. Shielding gas CO₂ and MIG active-gas mixtures are excluded from this TIG tool.

Machine, torch and gas adjustments — optional

Machine maximum current (A) Torch current rating (A) Use its rating for AC/DC and the applicable cooling/duty cycle. Your WPS / machine-chart current (A) Useful outside the built-in 0.61–4.76 mm chart. Must match the actual joint and position. Your gas flow (L/min) Flow rate, not cylinder pressure. Check while gas flows. Pre-flow (seconds) Post-flow (seconds) Job / machine reference

AC aluminum controls — optional

A common inverter reference is 75% EN / 25% EP. EN and EP percentages total 100%; machines may display either one or a proprietary scale. Read the manual before copying a number. The frequency example is 90 Hz from the Lincoln Square Wave TIG 200 guide, not a universal optimum.

AC balance value (%) A blank value always means the 75% EN example, regardless of the display-unit choice. Your machine displays AC frequency (Hz)

Pulse calculator — optional

Pulse is OFF by default. Enter your own procedure values to calculate rectangular-pulse average current. This does not recommend peak/background settings or prove adequate fusion.

Pulse Peak current (A) Background current (% of peak) Time at peak (%) Pulses per second (Hz) Pulse Hz and AC frequency Hz are different controls.

Measured DC arc-energy calculation — optional

Use actual average welding readings and travel speed. AC and pulsed waveform power need appropriate measurement; this simple equation is a DC estimate and does not include thermal efficiency.

Measured average current (A) Measured arc voltage (V) Travel speed (mm/min)

Your TIG settings

Calculate to see the numeric references and selected setup.

Prepare, test and adjust

Identify the base alloy and select compatible filler.
Clean the metal, filler and tungsten; use suitable PPE, ventilation and fire controls.
Check polarity, torch/cooling limits and machine duty cycle.
Practice on matching scrap. Control the pool; inspect fusion, penetration and required weld size.

Quick troubleshooting

Tungsten melts: check polarity, AC balance, current and electrode size.

Porosity: check contamination, leaks, drafts and shielding. More flow is not always better.

Dark stainless root: check required back purging and the procedure.

Crater: finish with controlled current reduction and filler as required; maintain shielding after stopping.

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