TFS: How to Weld Thick Metal to Thin Metal 

How to back purge: ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-AIRWMhoke9I.html

what tungsten and filler rod were used in this video? did you keep the cfh around 20+?

Great video, thanks! One question thoug, how can you have your electrode stick out so far? Is that a special cup for the purpose?

Appreciate the metric sizes being mentioned aswell! Getting better at mental metric/imperial conversion, but nice to not have it distract from the rest of the video and explanations :)

I just referred back to this video and it is still excellent. It’s a shame I can’t like it twice! Thank you so much for the time and effort you put in to recording them. It is so helpful!

What size filler were you using in this?

A lot of experience passed on to us. All this great information so hopefully when the good the bad or the ugly hits, we will know why and can proceed accordingly. Thanks again Justin.

From someone who taught and worked emergency services for >25 yrs., you Sir are an excellent instructor an communicator. Your explanation of rationale and technique are exemplary. I thank you. Please keep up the great work!

Great video, thanks! This is pretty much the same as other forms of welding from what I understand. I was always told to focus the heat on the thicker piece.

Can you do the same thing but with the tubes welded to a thin sheet that you don't want to warp?

When doing a tack like this I concentrate on the thick part. Wait for the puddle, and move it briefly to the thin part, which is now heated. A puddle forms almost instantly, and then I move it away. You can do it either way, but I regard it as safer starting on the heavier part. Of course, a lot of it is skill. If you are new to this, starting on the thin part is more dangerous, because it can be difficult, without experience, to tell when you’ve heated that thin tube enough, and you may be uncertain enough to leave it just a bit too long, and punch through. But when puddling on the thick part first, and that puddle forms on the thin part when you move the tip towards it, you will see them conjoin, so it’s easier to know that it’s done.

Hi, great video. I’m a newbe in tig and was just wondering how did you know that 100amps is the right amperage ? Rule of thumb for SS I think is around 35amps per mm ..... So is there a compromise between 10mm thick base and 1.6mm tube or how do you decide at which apms to start ? Thank you.

Like the shorter video. I don't always have time to watch the longer ones.Can you make some more at around this length? Do you only use Everlast welders? Thinking about getting a tig welder and was leaning towards Everlast

How long did it take you to be able to spin that practice piece on your finger without dropping it lol great videos

great video ..appreciate the detail shots and explanation

Love the channel and your an excellent teacher! Much appreciated

This video is exactly what I needed, thanks. In my application I'm welding 11 gauge to 3/8 plate MS, what amperage should I be using?

What a great video and great shot and technique of the tac weld. I could have used this same technique just the other day trying to weld 14 gauge mild steel rectangular tubing and not burn through the edge pieces!!

We don't Purge anything we weld here at our shop since we're not a code shop and we weld all stainless, sometimes aluminum. I was hoping to get some tips on how to not sponge through while welding thick to thin (currently I'm welding 12guage to 7guage (basically in the third configuration you showed)), but you absolutely obliterated it. You sponged through on the entire length of your welds except for your stops and starts. If I welded it like that here I'd probably get fired. I'm basically having to use the tungsten and filler wire to "splash" the puddle up onto the 12guage and the come back down and move to the next spot to create the ripples. Not trying to be mean here; just sharing how we would view that at our shop. I guess technically the way we do things here, we're not quite getting full penetration, but from my perspective, you got more than 100% penetration (like 110, 120, or 130% penetration) since it was starting to come out the other side (sponge through). My goal with what I'm doing is to get more penetration on the 7guage by focusing on it longer during each dime or bead or (I'm going to call them ripples) each ripple, then splash the 12 Guage, shove the rode, and move on. I'm currently at 143amps. I just have to adjust my speed to make sure I don't sponge through, and make sure I push enough rod (filler wire). I don't have the luxury of a pedal. It's just locked in at whatever amperage I set and it's either lift arc, or my dredded scratch start.

Great Video. This is true also for MIG, and Stick. Weld from thick and wash up to the thin. I see you run a lot of stick out. I'll have to try that much on my next TIG weld. Thanks.

How much cfm you working with with that stickout?

Dat stickout doe...

Q: Can we purge this kind of things with just peace of solid carbon dioxide? Solid carbon dioxide is cheap.

Awe oh my God justin I love ur vidoes😭😭 always helps me out when I'm in a pitch!! Always use ur vids for reference thank u brother!!! Keep being awesome!

Hi Justin, need Your advice or maybbe it could be idea for new episode. Im strugling with tig weld of two 2,5mm steel wires in parallell on bit long distance. Could You giive any hint?

Thanks for sharing. I’d love to see it done with with some aluminum foil Purge gas and show us the results. It’s cheap to purge with foil block off and. A small hose from the argon reg

Do u have an up to date video of this on mig welding???????????

Awesome video! Thanks for the tips! I will be practicing again today!!

I'm wondering what happens to the shielding gas with so much tungsten sticking out. We're taught to have very little tungsten showing while welding, although the cup would obviously get in the way here.

This was very timely for me. What would we do without RU-vid? Thanks!

I just started trying to Tig. My teacher (friend) has me using a much smaller cup and also to only let the tip stick out about 4mm from the edge of the cup. Where in this vid, you have a massive cup and the tip sticks out a mile! Is this necessary because you are welding inside a 'corner'?

Nicely done presentation. One question for you.. It looks like you are using an old skool welding helmet without electronic auto darkening feature. Why that choice?

The old way "consistent heat" you know what I'm saying

What size of tungsten and filler rod where you using. Also great video.

Focus ha I think I’m ADD 🤣🤣🤣 thanks for the tip man it definitely help me to focus people.......

how do you make it that the flange ( 10 mm thick ) will not bend because of the heat and when cool down again?

Your teaching commentary is excellent thank you

Thank you very much, super helpful... You Rock

Awesome video! Thanks for the info!!

Hey Justin, new to fabrication, and to tig, you mention here the welds are much weaker when not back purged, I'm welding lots of 20mm x 40mm 1.5mm wall 304 box section at the moment, is back purging really needed?

How to tig weld thin to thick, good information but put that in the header, I am a lowly production welder with only mig and pulse mig at my disposal. Last night was welding expanded metal to 14 gauge to 3/16. And took way more time than I should have. Wish I could just whip out a tig torch for random parts.

What do you mean by purged, I'm unclear. Thanks Ken.

I understand you say where the focus of the heat need to be, but what about the filler rod? Do you place it up on the wall of the pipe and let gravity pull it down or place it right in the groove and drag it up with the torch?

You're still not properly welding thin to thick if you are blistering through the thin material.

How do you combat the undercut that you get sometimes when tigging heavy material? I've tried adding more filler but it still undercuts on the edge of the weld, even if go high or low with the amperage. If you focus your arc towards the undercut it doesn't help either. Usually on cast steel but sometimes just regular old mild steel?

do you have to purge if you go for a 2nd pass from the inside at half penetration?

what an invaluable tutorial. Thank you very much for "the detail tutorial. By the way, I still have a problem in the way to devide a 100cm x 10cm x 1cm raw SLD Hitachi D-2 steel material to be 2 pieces of it sizing 100cm x 4.95cm x 1cm "without making a big chage of the quality of the material at the line of cutting. I do not know what is the best way to do it with. May be you have some advices for me to learn with. THank you very much again for each of your knowledge sharing. GBU always.

What size cup were you using. How critical is the cup size here. Was this a gas lens etc . Thanks

Hi Justin why how did you work out to use 100 amps for these welds thanks Jeff

So why do these videos if you're not going to purge the shit and show how to do it correctly?

Great video once again.

Can you make thin metal to thick????

Could you do one for welding bungs to 1.5mm tube. Im really struggling to do 1/8npt fittings to pipes without completely mashing up the bung/threads itself :(

Great video man. Was that a HTP TLP I saw up on the Great Wall of welders? What an awesome machine. Thanks for the flange tube focus point for puddle I always struggle with where do I focus the tungsten. I always struggle with getting a good fast tac too I have to get a puddle to tac.

That black on the back is called superintendent or carbide precipitation it has to do with that stainless not being purged but also more so that you amperage is to hung and travel speed to slow the grate thing about stainless is it is stronger thus a smaller bead is ok

How does back purging work for flat stainless?

What do you mean by Purge?

Can i used tig on brass sheet? Please reply,,, thank you

jeff luts doesnt back purge lol he get mad when someone tells him you have to lol

G'day what I would like to see a video of is welding aluminium 2"od tube 1/16 wall to the end of 2"id pipe 1/4 wall the two pipes sit inside each other by 1/4" because I'm just burning the thin tube away

Good clip, like everytime! But, with stainless, it's easy weld! I've allways little problems with 6061 and other AL. For example, at the wastegate 25x2mm welding to 60x2mm. The small tube allways runs away.... :-D

Much Appreciated Tutorial - Thank you

I will often preheat the thick flange a little bit.

Thank you thank you thank you!

If you look in the right hand side of the weld inside the red circle long enough at about the 3:40 mark you can see a dolls face

did you preheat that thick piece of metal?

Great tutorial! Just found you. Will subscribe

I am thinking about an everlast, it looks like all you run? It's AHP or everlast, do have an opinion? Thanks

Hey Justin what size cup are you using

Excellent video - thanks

Learned alot. Thanks for the instructive video.

Do you have to purge when you are doing that flush mount weld (your last one ) and if so how would you do that?

I assume the concept is the same for MIG welding? If possible, would you be able to put a quicker video showing the same concepts with MIG? Something like welding rollbar backing plates to a factory floor plan. Thanks.

What do you mean when you say you didn't purge the weld? Is this in addition to the torch gas?

Question. I'm learning to TIG but thought your tungsten had to be closer to the cup. Why was yours so far out?

What type of metal tube is commonly used in muffler shops?

You would have made a great instructor. but there is no money in that.

Thx brother

What size cup are using?...that's a ton of stick out on your tungsten...Thanks for the video.

Do you have or can you make a video like this one with the purging to see inside of pipe afterwards? Great video btw good tips

+1 for the Ticon sticker!

Great video. Thank you.

Once more in aluMINium please

That's crazy stick out what kind of gas flow are you using with that cup haha nice video man

AWESOME vid! You should make a video of how to weld a pipe/tube to a vband flange.

HOW do you PURGE???

Might have been asked,but didnt see it when i looked. Instead of back purging whats your opinion on using Solar flux for stainless in this type of situation?

That stick out 😱

Great video and great tips

well explained!

How much CFH of argon are you running with that long of a stick out? Gas lens?

It seems to me that the tungsten stick out is HUGE! Can you do that because of the Furick cup? Did you get that from Jody?

what is the amp.

Awesome video

Thanks Justin

very nice!

Thanks man!

dontcha HATE seeing that blue flash of light when tig welding!! lol man i hate it! oh well tho... we all take a little dip in the puddle from time to time huh.

How can you weld thin to thick metal

one of the best channels on youtube along with the fab forums channel.... keep makin them videos man....