How to Pick the Right Size TIG Filler Rod - Kevin Caron
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- čas přidán 9. 09. 2024
- From www.kevincaron.com - Artist Kevin Caron explains how to pick the TIG filler rod that is right for your amperage, metal gauge and project ....
A viewer, Richard, pointed out that there isn't much if any advice on how to select the right filler rod. He was trying to weld 16 gauge with a 1/8" filler rod, and it wasn't going well. He was blowing holes in the metal and making a mess. So how do you pick the right size filler rod for the job?
Caron likes to use a bigger diameter rod depending upon the amperage. So above, say, 80 amps, he's using a 3/32nd or 1/8" rod. It also depends upon how big a fillet you want - how big of a weld you want and hole you have to fill. More metal - 1/8" - bigger weld.
You also have to balance that with the amperage. Using less amperage for thinner base metal means you're going to have a harder time melting and flowing a larger filler rod. Suddenly, there's a lot to think about!
Caron is going to put on his welding helmet and fire up his AHP AlphaTIG 200X. He's going to set the amperage at 55 amps to weld some 16 gauge steel, weld with an 1/8" filler rod, then weld with some 1/16" without changing the amperage, just to show you the difference the size of the rod makes.
He welds with the 1/8" welding rod, noticing how long it takes for it to melt. The 1/16" rod works a lot better!
He shows the results. "Richard, you're absolutely correct, man!" Caron says. The weld done with the 1/8" rod shows where it got hot and tried to blow through the steel. Part of the reason is that Caron had to stay in one place so long to get the large rod to melt. The weld done with 1/16" rod looks pretty good and went a lot quicker, letting him keep up with the heat, because the rod is smaller.
Thank you, Richard!
Caron is ready to go back to work, so you have time to visit www.kevincaron.com to see more how-to videos, sign up for his newsletter, and see what's going on in the "Work in progress" section.
Well, you might stick around for another moment to see another member of Caron's team speak his piece ....
"Inspired sculpture for public & private places."
Artist Kevin Caron has been sculpting full time since 2006. You can see his more than 45 commissions in public and private places coast-to-coast and online at www.kevincaron.com.
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Great video Kevin. This is definitely a topic that's not usually touched on on most welding websites. Thanks for revealing the magic! Thanks to Richard for bringing this up!
Wow I can't believe there's a video for it. A really essential part of learning to tig, thanks for making this video! I've got a student I can't wait to show this to.
And Thanks Richard!
I’m a beginner this videos a big help 4 years later thank you
Thank you for watching and posting. Welcome to the club!
Finally got around to watching this video. Saved it to a playlist to find it easier when the TIG welder finally happens. I smell an Everlast 160sth in my future.
Nice little machine! Sure it will work very well for you..
Kevin Caron, Artist But before can get the Everlast 160sth, need to get a cabin built. Definitely want one, just like that metal cutting circular saw you did a video of. So many shop toys, so little money. LOL, kind of like a starving artist, buy what you can when you can.
Thanks Kevin, been trying to weld some thin Aluminum all week with a 3/32 T and filler. Will not work on low amps. This was a great topic to cover. I think anything below 1/8 th should be 1/16th T and 1/16 filler. Appreciate the video work.
Whatever works for you is the correct way far as I see.
thanks for watching.
I snorted at the end...rofl....too funny! it was great to hear from you the other day my friend.
Oh God, what did she post now!?
Can't wait to get started tig welding with my everlast. I really want to learn how to tig weld stainless.
Thanks Richard
The general rule of thumb is to match the tungsten to the filler rod and to the base metal. I weld a lot of panel steel and have all three the same thickness. I use mig wire as a cheap filler rod by cutting lengths I need and make them straight by clamping one end in the vice and the other end in my cordless drill. Pull it taught and then give the trigger a pull for a few seconds to twist the wire perfectly straight.
Very good information. Why all the splatter or flying sparks. I'm not accustomed to seeing that with TIG.
Dirty tungsten or metal I guess.
Gas flow too low?
This was exactly what I did today. And I thought steel would be a piece of cake.
Always something new to learn for sure.
Kermit gets to weld when he stops being flammable.
And you DON'T want to see him using a lathe!!
Makes perfect sense to me.
good points kevin, beginners better stick to the guidelines you laid perfectly here. as they practice and practice and practice every welder will develop his technique and then will know how to play with the variables to adapt the situation. the cooling effect of the mass of the rod on the weld puddle is never well explained to beginners but you did an excellent job. take care. pete
Thanks, I try to keep it easy enough so I understand what I am talking about. Though sometimes I find myself asking "What did I just say?!".
Hey Kevin, When I did my Tig Welding course at Tech. College back in 1992 I was told by the instuctor about "The 3 second rule" i.e. if it takes longer than 3 seconds to melt the plate , you need more Amps. It would also follow that if you are moving at about 1 seconds per "dab" then your filler rod MUST melt as fast as that. Also take into account that the larger the filler rod, the more it "chills" the puddle. So if you want a fast moving small weld, then you need a small filler rod.
Great points Scott!
I Found that thickness of rod should be the same or slightly thinner than thickness of metal.Thanks for your tips.
Thanks for watching, it's a team effort!
gl finding me 25mm rod
Some of it depends on your application too... There are ready cheats to using the wrong filler rod to get the right job done with the wrong sized filler & sometimes I prefer to do it.
If your parent metal is thin enough, say half the size of your filler... Start with low amps from the pedal on the joint as normal, but moving your focus to the filler is the trick. Make sure your filler is grounded in the joint and move your arc onto the filler rod and step up the amps to weld. The filler will fall into place and your filler will behave as a heatsink from that point onward.
Once you have that tacked up with a good weld, start welding on the joint where you stopped at and it'll take the filler easily.
You can walk around prior to see how your penetration went before you start, it should be uniform front and back. Depth and width should look the same from the front and back.
It makes a fast moving job a bit slower too, if it's really thin metal you're welding on. I use it on metal less than 1mm where I need stainless filler with a parent metal that has torn and gives you some play to get it done without blowing it out. If you don't need a big weld showing on the front and my scenarios... I can't have any weld showing where I was welding on the front, grind the front off and the backside is a mirror image of the front profile. 100% fine pattern on the back...
If it's aluminum, good luck on that! You'll want the right filler rod/wire for the job... Aluminum doesn't afford you any luxury other than becoming a better welder through the school of hard knocks! May the force be with your poor filler hand! ✍🏼
Good points all around!
Thanks you for sharing your knowledge!
Thanks Richard.
I had this problem a few weeks ago. Had a big gap to fill using a somewhat low amp Tig machine, 165amp, and just couldn't get the 1/8th inch rod to melt. I'm going to try the same set up again and use the 1/16th to see how it fills in the gap.
I'm think it would make for the same issue using stick. I tried using 3/32 rod with the same problem, the 165 inverter machine just wasn't getting my puddle hot enough.
Sometimes you just need more power!
Could it be generally said that the metal dictates the amperage and that amperage dictates the filler rod and electrode size?
You are right on the money!
Good job Kevin.......Oh ya
Thaaannnk.....Yooouuu Richard.
Well put
Thanks, was a little worried about this one..
sounds like your gas flow is pretty high, I've found that too much gas cn make for an unstable arc but I could be wrong.
Can someone pleasssssssssse help me with this inches, gauges and diameters as when I am from South Africa its difficult for me to understand clearly as I love to learn so much!
I have the same cap and performance hood. makes me think of the Flintstones print haha, looks good on you bud
sparky.
Good coverage on rods, heat input should balance rod to base being welded. I would rather error in favor of a smaller rod and more dabs. Also, I noticed some sparks being thrown off when you tested the ⅛" rod etc. What was up with that, contamination or?
Looks like your amps were still too low for 1/16. The weld looks too hot.
I was told 1/16th was more useful than 3/32nd when using 80-150 amps. This true? I just bought 10lb of 1/16th tig filler.
I’m mainly looking to do sheet metal on my old c10 and maybe a transmission cross member mount. Can 1/16th penetrate this properly at 120 - 150amps or do I need to go buy 3/32nd instead?
The thickness of the filler rod has nothing to do with penetration. You can use 1/16th at 150 amps but you have to really fly when you are feeding the puddle. I like the 3/32 over 130 amps.
I'll start right away 😂
Is there a chart that one can go by?
Not that I have but I am sure they are out there.
I think I saw a video that said to use the same size filler rod as the tungsten size.
that was probably Weld.com with Mr Tig.
I always like watching your videos Kevin. I want to practice with my powertig more at some point. Just no spare time for practice.
I find myself getting rusty after just a couple of weeks of not using the tig. Have to keep at it to keep getting better.
Hey Kevin Whatcha doing?
I retired 6 months ago and now have time for things that I want to do first is getting out of the North East and getting a BIG shop/work area.
If you don't mind my asking how big is your shop and about how much to construct with 230/400 amps?
Hope I'm not being to personal.
It's just over 1800 Sq. Feet.
Kevin, I have to weld steel nuts to Aluminum for a gate opener, what rod can I use? I hear about this Alum-Steel, have you used the stuff? Thanks Forest
Have never tried it but here is the website,, alumasteeltigrod.com
Let me know how it works please!
why are you getting sparking? To high gas set up?
That or the metal was not clean enough. My bad.
Something to do with those scrap pieces of mig wire, real small tig wire. Or fold them in half put one end in a drill and give it a twist to make a bigger piece of tig wire.
Did a video doing that with a drill awhile back.
Now that you mention it, I think I remember that. I am getting old.
+bc65925 after I saw it I started saving all my scrap wire and doing this with them. Genius, lol!
.045 for that thin metal
If it sticks to the puddle, almost like its magnetic, go down a size....
That is interesting, I have had that "magnetic" reaction before, what causes it.
Kiven One better than filler rods size to metal thinkness. What size tungsten to metal thinkness when do you change the next od tungsten size for thinkness of metal. what is the range of a given OD tungsten I did wonder where miss piggy had emergraed to from the UK
I normally run 1/16to 16gauge and 3/32to 1/8, above 1/8 or over about 100amps I will go to 1/8th inch tungsten.
Sir what typer filler rod you have been trying using,is it brass or copper rod,can you pls give a name
I use ER 70s for steel and ER4043 for aluminum.
It looks like copper because it is copper plated, but mostly it is steel.
thanks
Which filler rod should be used for AISI 4130 with TIG WELD?
Try 80S-D2 for ChromeMoly. Seems to work pretty good.
Shubham, ER 80 S- D2
I swear I heard Miss Piggy's coming through Kermit!
Busted!!
Any suggestions for TIG welding 26 gauge? .40 Tungsten and filler?
I have found large amounts of vodka helps!
I have read that people sometimes use the .023 or .035 ER70 MIG wire as filler rod on extremely thin material such as your 26 gauge. I have not had the chance to try it myself yet, but it would be worth a shot. Good Luck.
Thank you!! Keep up the beautiful artwork! I'm a Disabled Veteran (68 years young) just starting to do small stuff for the family to see how it goes. The 1,000 lbs of 26 gauge was free 😎
.35
Thomas Quinlan Thank you!
Is it my imagination Kevin or was there more than a normal amount of spatter ?
i was wondering the same thing
I think he was getting the plate that hot waiting for the "telegraph pole" filler rod to heat up that the plate was basically vaporizing.
Was your gas on? Very sparky.
Oh yeah, probably I forgot to clean the metal enough.
Hey Kevin can you take a look at my tig weld on my channel and give me some advice please ?
Need to know the settings you are using as well as the filler rod and metal. Mostly it looks like you need to slow down and practice. Start counting in your head "one one thousand" and dab at the same time every time.
Kevin Caron, Artist im using 1/8 inch es70r2 at 80 amps
Way too cold! Turn the amps up to 125 and try again.
Kevin Caron, Artist would it help if I used 1/16 rod ?
Sure, amps around 80 for 1/16 should work great.
Is it just me or is it too hot
It was only about 105f in the shop that day. Everything was a little too hot!
lol all was like the end
Guest voice!