Welding may seem like a simple task. How hard would it be to join two separate pieces of metal together into one solid piece?
It seems like with the right welding equipment, anyone can accomplish such a task with ease.
However, each welder has a specific use; anyone can make the mistake of using the same welder for every project and end up with bad results.
Not all metals are the same, they are of various types, sizes, and densities, which really begs the question—what sort of welding equipment is best for working with thin metals?
Stick around and let’s go over some of the options we’ve laid out for you that might help with your search.
The Best Welder for Thin Metals
If you ask any experienced welding professional worth their salt about the best welder for thin metal projects, the most likely answer they’ll give you is: The TIG welder.
By and large, the TIG welder has been considered by many in the industrial sector—experts and professionals alike—as extremely flexible when it comes to both the equipment and the process itself.
Due to its very nature, welding professionals and equivalents in the industry have been able to bond materials together that are on the smaller side. These materials also tend to be thinner with regard to density.
To bring in technical terms of the process, TIG welding uses what is called a non-consumable tungsten-made electrode. With this electrode, it serves as the means by which the metal is heated during the welding (or bonding) process.
In comparison to MIG welding, the TIG welding process has been considered to be much slower. That it can result in longer lead times during fabrication is a fact, as well as having higher production costs in many cases.
At the same time, professionals known to use TIG welding are well-versed in certain specific skill sets. Acquisition of these skill sets requires training to have the necessary precision to reach accuracy that is considered industry-standard.
That being said, TIG welding boasts a greater level of control in spite (or perhaps because) of its meticulous nature to master. A professional well-versed in the process often presents a weld that blends function and durability with a smooth, sleek aesthetic that requires little touch-up time once fabrication is done.
However, don’t just take our word for it. Below, we’ve put together a small list for you to look at presenting what have been determined to be the best welders for thin metals in the market so far.
Brand | Model | Welding Process Type | Output Amperage | Foot Pedal | Input Voltage | Weight | Dimensions |
Lotos Technology | TIG 200 1H-4HPT-NF 6E | TIG and STICK | 200AMP Max output | Included | Automatic dual voltage / dual frequency (110/220-volt 50/60Hz) | 58 Lbs | 28 x 13 x 17 inches |
Weldpro | TIGACDC20 0GD | TIG and STICK | 200AMP Max output | Included | 110v/240v 50/60 Hz | 53 Lbs | 17.6×7.9×16 inches |
Lincoln Electric | Square Wave Tig 200 | TIG and STICK | 200AMP Max | Included | 110v/240v 50/60 Hz | 73 Lbs | 22 x 13.1 x 21 inches |
PRIMEWELD | TIG225X | TIG and STICK | 225AMP Max output | Included | 110v/240v 50/60 Hz | 90 Lbs | 24 x 19 x 12 inches |
Weldpro | MIG200GDsv | Multi-process (Mig, Lift, Stick, and Tig) | 200AMP Max | Not Included | 110v/240v 50/60 Hz | 30.4 Lbs | 17.72 x 8.66 x 14.96 inches |
For reference, the welders listed above were considered because of their features and value, rather than just their selling price or the name of the respective brands attached to them.
As the list shows, our recommended choice for the best welder for thin metal is the Lotos Technology TIG 200GD for a number of reasons that we’ll be exploring further along. But for the most part, it was a clear choice due to its numerous features and user-friendly design.
Top Five Pick for Best Welder for Thin Metals
Lotos Technology, TIG 200 1H-4HPT-NF 6E
- Its primary feature is its capacity for welding different kinds of materials like aluminum and stainless steel. On that note, it’s also equipped for both TIG and stick welding which opens up versatile uses.
- Its input being automatic dual voltage lets the TIG 200 operate with most power outlets (both conventional and/or residential).
- Precision control of the weld heat is attributed to the foot pedal included in the full kit, and an efficient cooling system allows for multiple and continuous welds with shorter down-times in between.
- Its cooling system, however, may be prone to gathering dust during the cooling periods.
Weldpro, TIGACDC20 0GD
- While it may not boast as much versatility in terms of multi-material capability, the TIGACDC20 is an adequate tool when it comes to either do-it-yourself projects or jobs that require a more professional touch.
- In addition to the included foot pedal, the torch is equipped with a trigger for projects with welds that put the worker into an awkward or hard-to-maneuver angle.
- The touchpad is fully digital and is user-friendly, which may also take some getting used to for users more used to dials and knobs on equipment.
Lincoln Electric, Square Wave TIG 200
- This one is equipped for both TIG or stick welding for versatile usage and can handle both aluminum and stainless steel easily. Also included in the kit are additional accessories.
- It has dual voltage capability, which means that it can be used with most power outlets.
- The compact version of the TIG 200 sits at just 47lbs, making it a more portable choice to bring where the work takes you.
- In terms of reach, the ground cable may be shorter than expected.
PRIMEWELD, TIG225X
- It has the capacity for handling multiple types of materials, like stainless steel, aluminum, and other alloys.
- Overheating is not a primary issue due to the cooling system geared towards power cooling. It also includes an IGBT inverter and a PWM modulator making it energy-efficient in spite of the powerful cooling.
- The TIG225X is also dual voltage capable and will work with most power outlets.
- The pedal and torch are U.S.A.-manufactured but may require an eventual upgrade.
- For project workloads that require a heavy-duty weld, a water-cooling system might be better.
Weldpro, MIG200GDsv
- Among the five choices, the MIG200GDsv is the most compact. At just a little over 30lbs, it makes the entirety of the rig easily transportable for easy storage and travel.
- Despite the model name, it can actually perform different welding process types like MIG, TIG, and even Flux Core.
- It can switch between voltages which allows for a more flexible welding process depending on the material.
- It also includes a wide LCD screen to help you with adjustments as well as overload protection.
- However, a foot pedal is not included.
| Product | Pros | Cons |
| Lotos Technology, TIG 200 1H-4HPT-NF 6E | Compatible with most materials Works with most outlets Precision controls | Prone to gathering dust |
| Weldpro, TIGACDC20 0GD | Foot pedal and trigger combo User-friendly digital touchpad | Not as versatile with materials |
| Lincoln Electric, Square Wave TIG 200 | Lots of additional accessories Works with most outlets Compact and portable | Short ground cable |
| PRIMEWELD, TIG225X | Can work with lots of material Power cooling Works with most outlets | May need parts upgrades or replacements not suited for heavy-duty projects |
| Weldpro, MIG200GDsv | Compact and portable Flexible, can switch voltages Overload protection | Foot pedal not included |
What to Look for in the Best Welder for Thin Metal
Budget
In terms of your purchase, perhaps the first thing that really matters (aside from the features that your choice of welder claims to have) would be your budget as well as the length and extent of its warranty.
As far as the budget is concerned, it’s mostly a chief concern if you’re just starting to dip your toes (or dive headlong) into the industry. Work with something that fits your needs and don’t be afraid to spend a little bit more for quality and effectiveness. An ideal warranty coverage would be at least a year up to three when choosing something meant for heavy-duty projects and frequent use.
Foot pedal
Next, find a welder that includes a foot pedal in the kit itself. When considering a lot of welding jobs that work on thin metal, a foot pedal is the most efficient way to control the heat during a weld.
The usefulness of the foot pedal shines most especially if you find yourself welding in a position where controlling the heat any other way would hurt the work being done.
Portability
Lastly, you’re looking for a rig that’s on the portable side, especially if the work will be taking you around the site more often than you’re staying still in one area.
A good portable machine is expected to be in the range of 40-50 lbs, give or take. It will cost money to get yourself a cart to haul a heavier rig around and time to put it up and take it down each time you have to move otherwise.
Welding It All Together
While we haven’t exactly given a proper crash course into welding (especially when using thinner metals), we hope the information compiled here has at least given you a starting point on TIG welding, getting your equipment setup, and what to look for when you’re after the best welder for thin metals.
All in all, though, the type of welder you get and the materials they can work on are not as essential as the experience and skill that welding will give you with more and more accomplished projects under your belt.
Welding is a learning process that is always getting refined as much as each of your welds is. Pick a welder, work with it as best you can, get comfortable with it, and you’ll be taking on projects in no time.
FAQs Concerning Thin Metal Welds
📌 What is the best power source for welding thin stainless steel?
An inverter power source can offer an arc that starts at high frequency but narrows down to avoid burning through the material you’re working on. You can do this by setting the machine to a straight polarity setting or direct current electrode negative (DCEN).
📌 What are the recommended parameters for welding thin materials?
Generally speaking, 1 A is the standard for every 0.001 inch of material that’s being welded using the gas-tungsten-arc-welding (GTAW) process. In lieu of practical experience, you can begin your welding process by achieving an AC balance of 70-75 percent electrode negative (EN) first, as well as 120Hz of AC frequency. The effect these settings can have will generally provide a stable arc that makes for smooth control during the weld-work.
📌 What type of welding torch is best for thin materials?
A GTAW torch with a rate of 150-300 A is the standard when welding materials that tend to be a quarter-inch (1⁄4-in.) or thinner. In terms of cost, air-cooled torches will cost less than ones equipped with water-cooling systems, most especially when a separate cooler doesn’t have to be a factor.
📌 What type of tungsten should be used when welding thin materials?
A pointed 2-percent seriated tungsten electrode acts as the general reference point for materials at a quarter inch (1⁄4 in.) or thinner than that. That type of electrode makes for a good arc at low amperage settings specifically for thin metals.
