TIG amps by material thickness
Start points by material and thickness — the pedal does the rest.
| Thickness | Steel (DCEN) | Stainless | Aluminum (AC) | Tungsten | Filler |
|---|---|---|---|---|---|
| 0.030" (sheet) | 25–35 A | 20–30 A | 40–60 A | 1/16" | 1/16" |
| 0.062" (16 ga) | 55–70 A | 45–60 A | 80–110 A | 1/16" | 1/16" |
| 0.093" (13 ga) | 85–100 A | 70–85 A | 120–150 A | 3/32" | 3/32" |
| 0.125" (1/8") | 115–135 A | 95–115 A | 160–200 A | 3/32" | 3/32" |
| 0.187" (3/16") | 160–190 A | 140–170 A | 220–260 A | 1/8" | 1/8" |
| 0.250" (1/4") | 200–240 A | 180–220 A | 280+ A | 1/8" | 1/8" |
Where the 1 A / 0.001" rule breaks
Aluminum: oxide layer eats heat on AC — run ~1.5× and use a #7 or larger cup with argon. Thin stainless: heat discolors and warps fast; stay at the bottom of the range and back the pedal off mid-bead. Over 1/4": preheat to 200–300°F or no rule survives the puddle.
AC balance for aluminum
Modern inverters: start at 65–70% electrode negative, 100–120 Hz frequency for a tight arc on 0.062–0.125". Cleaning action too wide means too much electrode positive and a balling tungsten.
Torch setup
Tungsten, cups, and filler recommendations coming after affiliate approval.