Top 5 TIG Welding Mistakes Beginners Make (and How to Fix Them)

Are you just getting started with TIG welding? Do your welds look rough, inconsistent, or downright sketchy?

Don’t worry—you’re not the only one. TIG takes time to get the hang of, and it’s totally normal to make a few mistakes when you’re learning. The key is knowing what those mistakes are and how to fix them.

In this article, I’ll walk you through five of the most common TIG welding mistakes beginners make, based on a video from my YouTube channel (worth checking out if you're more of a visual learner).

Let’s get into it!

1. Contaminated Tungsten

Tungsten contamination is probably the most common issue for beginner welders. It happens when your tungsten touches the workpiece or filler rod, and picks up crap it’s not supposed to. You’ll end up with an unstable arc that has zero accuracy leading to messy welds, and a lot of frustration.

Fix it:
If it’s just a bit contaminated, give it a clean with a belt sander (do it outside) Make sure that when you grind you use a clean belt for tungstens only, and you grind lengthwise to the tungsten. However if it's cracked or damaged—just swap it out. Keep a few clean tungstens ready to go so you’re not wasting time. And most importantly, try not to touch the tungsten to anything while you’re welding.

2. Not Enough Post Flow

Post flow is the shielding gas that keeps flowing after you stop the arc. It cools the tungsten and protects your weld from oxidation. If your post flow is too short, the tungsten gets discoloured and your next weld will likely be contaminated before you even strike an arc. This is why it's common to see dirty little puffs at the start of your passes sometimes. That's the contamination from the end of the previous weld being blown into the start of the next one.

Fix it:
Adjust your post flow settings—start around 10 seconds and tweak from there depending on your weld size and amps. And don’t move your torch straight away when you finish a pass. Hold it in place until the tungsten cools properly. A clean, shiny tungsten is what you’re aiming for.

3. Bad Sight Lines

If you can’t see what you’re doing, it’s going to show in the weld. Simple as that.

Fix it:
Set yourself up properly before striking an arc. Adjust your workpiece, get comfortable, and make sure you’ve got a clear view of the tungsten and weld puddle. Take breaks if your eyes are getting tired—welding fatigued never ends well.

4. Incorrect Standoff Distance

The gap between your tungsten and the workpiece matters more than you think. Too close and you risk dipping in and contaminating your tungsten. Too far and the arc becomes unstable and wide.

Fix it:
Keep your standoff distance consistent—I recommend a standoff distance equal to the thickness of your tungsten electrode. Practice holding that distance steady through the whole weld. It’ll feel weird at first, but you’ll build the control over time.

5. Taking On Joints You’re Not Ready For

TIG is precise. Trying to tackle complex joints before you’ve nailed the basics is a recipe for frustration.

Fix it:
Start with flat passes on a simple piece of clean plate and focus on consistency. Use what you learn to then move on to something like a butt joint after that, that's a big step that's worth celebrating! Once you’re confident with that one and can duplicate your results over and over, move on to corner or fillet welds. And don’t be afraid to repeat the same joint over and over until it clicks. It’s not about being fast—it’s about being solid.

Bonus Tip: Clean Everything

Clean metal = clean welds. TIG doesn’t hide anything. If there’s oil, dirt, or oxidation on your base material or filler rod, it’s going to show in your weld. Always take the time to prep properly.

Final Thoughts

Welding is a skill. You’re not going to get it perfect straight away, and that’s okay. These mistakes are all part of the learning curve—but if you can spot them early and fix them, you’ll save yourself a ton of time, money, and stress.

If you’re after more tips or want to see these fixes in action, watch the episode here 

You’ll find no-fluff tutorials, gear breakdowns, and plenty of real-world advice.

Keep practicing—and enjoy the process.

Dusty.