TIG starting calculator

Steel ≈ 1 A per 0.001", stainless a bit less, aluminum a bit more on AC. Pedal up into the puddle — these are ceilings, not locked set-points.

Not a WPS. Practice estimates only. Not qualified to any welding code. Confirm against your machine manual and consumable data before production work.

Inputs

Metal

Thickness

Machine notes

Inverter AC aluminum

Start around 65–75% EN for penetration. Add cleaning if oxide won’t break. Frequency ~100–120 Hz is a common starting zone on many inverters.

Transformer / older machines

Balance controls differ. Use scrap and watch wetting — don’t chase inverter numbers on a transformer box.

Gas lens vs standard cup

Gas lens often lets you stick out farther with the same CFH. If the puddle sugar-coats or goes porous, check coverage before piling on amps.

Rules used

Carbon steel, DCEN: ≈ 1.0 A × thickness (thousandths).
Stainless, DCEN: ≈ 0.8 A × thousandths.
Aluminum, AC: ≈ 1.2 A × thousandths.
Above ~1/8" (3.2 mm), treat it as a first scrap guess only.

Check the bead photo MIG calculator

Cup size, gas lens, filler, and joint type all change heat needed.