The TIG Welding Process
Developed in the early 1940s for the aircraft industry, TIG (Tungsten Inert Gas) welding is a precision technique we've mastered at Freeform Furniture. Our TIG welder creates intense heat via an electrical arc between the tungsten electrode at the torch tip, the filler rod, and the workpiece. Tungsten, the same material used in light bulbs, generates enough heat here to melt metal effortlessly.
A ground cable attached to the workpiece or table safely directs excess electricity away, much like a lightning rod on a building.
To ensure strong, crack-free welds, we protect the molten metal from contaminants using argon gas. This inert gas flows from the tank through the torch, forming a protective shield around the weld pool until the metal solidifies.
Professional TIG welders cost $1,000 to $3,500; ours at Freeform Furniture is a reliable $2,800 model. For DIY projects, rent one from an industrial supplier for about $60/day, including safety gear.
Welding demands respect for its hazards: arcs produce 1,600°F heat and blinding light. Our welders always wear full-face welding masks to shield eyes, face, and neck from burns, plus leather gloves and long-sleeved jackets for hands and arms.
A standout feature on our unit is the remote amperage control via foot pedal, allowing precise heat adjustments mid-weld.
The process involves tack welding parts in place, filling the joints, and cleaning each weld.
Tack Welds
Tack welds temporarily hold assemblies in perfect alignment before final welding. Typically 1/2" to 3/4" long (never over 1"), their size and number depend on metal thickness and assembly complexity. We apply small tacks on one side with filler rod, cool, then tack the opposite side. This localized heating prevents warping until permanent welds are complete.
Fill Welds
At Freeform Furniture, all joints start with tacks, then get fully filled with molten filler rod for maximum strength. These are fillet welds—fusing metal at 90-degree corners, common in furniture but challenging for consistency. They require high heat input; our experience ensures proper penetration and fusion, avoiding hidden defects.
Weld Cleaning
Post-weld, we brush away oxidation (the blue discoloration) with a wire brush. This minimizes later polishing needs for a flawless finish.
Starting Your Own Water-Jet Cut Project
Ready for custom metalwork? Provide precise technical drawings and contact a local steel or marble fabricator with waterjet capabilities (check the yellow pages). Laser cutting works as a solid alternative if needed.
