How to Find the Best TIG Welder: TIG Welder Buyer’s Guide

A breakdown of top reviewed TIG Welders – 1. ESAB ET 141I AC/DC; 2. Miller TIG Diversion 180; 3. Lincoln Square Wave TIG 200; 4. Fronius MagicWave 230i

TIG (Tungsten Inert Gas) welding, also known as Gas Tungsten Arc Welding (GTAW), is a popular yet complicated welding process that works wonders on thin metals, especially aluminum. Its popularity stems in no small part from the cleanliness, precision, and aesthetically pleasing welds that experienced welders can achieve with it.

As for the welding machine itself, there are several components to a TIG welder, and you should become familiar with them before you begin comparison shopping. Those essential parts include:

• The torch lead that connects the welding machine to the torch
• A shielding gas hose attached to the welder
• The non-consumable tungsten electrode inside the torch and which one you should be using
• A replaceable ceramic cup
• Gas diffuser or gas lens
• A foot pedal to adjust amperage (this is not standard equipment on all welders)

With all the essential information in place, you can start comparing welding machines and not just run out and buy the first TIG welder for sale. Here are four top-rated and reviewed TIG welders (in no particular order).

Table of Contents

ESAB ET 141I AC/DC

Overview

The ESAB ET 141i is a multi-process welding machine providing two welding processes: TIG and Stick. The two-process package makes it possible to work on various metals, including stainless steel, mild steel, and aluminum. 

The ET 141i is highly portable with a total weight of just 48 pounds and preset controls for DIY projects. It offers the ability of running from a limited 120-volt power supply.

Pros and cons

Several advantages of the machine include:

• At around $1,571, it is a more budget-friendly
• Pre/post flow preset manages shielding gas
• Hot Start provides large current at the start of a weld
• Lift TIG Start offers consistent arc starting without high frequency

And a few disadvantages:

• The machine can’t run for an extended period without getting hot

Specifications

• Primary Voltage: 120 VAC
• Lead cord length: 10 ft.
• Maximum output: 140 A
• TIG welding output: 140 A/15.6 V @ 20% duty cycle; 75 A/13 V @ 60% duty cycle; and 60 A/12.4 V @ 100% duty cycle
• Stick welding output: 90 A/23.6 V @ 20% duty cycle
• Weight: 48.4 pounds
• Machine dimensions: H 15.75 in. x W 9.45 in. x L 17 in.

Miller TIG Diversion 180

The Miller Diversion 180 offers a host of features in its powerful TIG welder. Along with its versatility, the Diversion has established a reputation for making the welding process easier and more efficient. Because of this, it has become an ideal choice for both professionals and hobbyists.

The Diversion 180 has an easy-to-understand interface that guides operators through the setup process. The machine comes with a foot pedal and ergonomic TIG torch rated at 150 amps, and an inverter-based power source provides a smoother and more consistent arc.

The unit operates on dual voltages, while a "fan-on-demand" function turns on the cooling system only when necessary. This feature helps minimize noise, reduce power consumption, and prevents unwanted particles from entering the machine.

Pros and cons

The Miller Diversion 180 offers the following benefits:

• Dependable arc start
• Ergonomic and durable torch
• AC and DC capability so that you can weld both aluminum and steel
• Dual voltage plug for a quick change of the required power input
• Remote foot control
• Fan-on-demand prolongs the life of the unit and saves energy
• The easy-to-understand interface and digital display allow even beginners to use it flawlessly
• The use of inverter technology makes this unit both powerful and portable
• The auto post-flow feature prevents waste of gas and shields the electrode and weld zone

And on the downside:

• The $2,499 price tag may turn off some budget-minded buyers
• Not ideal for many industrial applications

Specifications

• Primary Voltage: 120/240 VAC
• Work cable length: 12 ft.
• Maximum output: 180 amps
• Welding output: 150 A at 16 V, 20% duty cycle
• Weight: 50 pounds
• Machine dimensions: H 17 in x W 9.875 in x D 23.875 in

Lincoln Square Wave TIG 200

The Lincoln Square Wave 200 offers extra versatility with the options of TIG and Stick welding. Because of this, welding operators can work on a more substantial variety of materials.

The Square Wave offers both AC TIG for welding aluminum and DC TIG for steel and stainless steel. The unit is dual voltage and comes with two power cords, one for each voltage. High-frequency (non-contact) start, pulse mode, and inverter technology add to the welder's list of features.

Pros and Cons

The positives:

• Lightweight and portable
• TIG and Stick capabilities
• AC and DC options
• Versatile machine that's easy to use
• Ideal welder for all skill levels
• Several adjustable features: amperage, voltage, AC balance, AC frequency, and pulse frequency
• Foot pedal included
• Simple interface

And a couple of negatives:

• Although it is highly rated by consumers, it's still a bit expensive at $2,099.00

Specifications

• Primary Voltage: 120/230 VAC
• Lead cord length: 12.5 ft.
• Maximum output: 200 amps
• TIG welding output: 40% duty cycle @ 100 amps (120 V) and 40% @ 160 amps (230 V)
• Weight: 46.5 pounds
• Machine dimensions: H 14 in x W 10.75 in x D 19.25 in

Fronius MagicWave 230i

A fully digitized TIG AC/DC power source, the Fronius MagicWave 230i is an advanced machine packed with features. Lightweight and portable, the machine is especially used to TIG weld aluminum.

The MagicWave features Active Wave technology, which reduces noise while providing the highest arc stability possible. Its intuitive menu navigation allows users the ability to toggle though settings with or without wearing gloves. Plus, Bluetooth capabilities offer connectivity with phones and welding helmets.

Pros and Cons

A few positives:

• Bluetooth connectivity with wireless devices
• Parts are made by Fronius and made specifically for the machine
• TAC function creates one single weld pool instead of two
• Touchdown ignition technology prevents electromagnetic interference
• Simple option for igniting the arc using HF Ignition feature
• Automatic cap-shaping saves time when welding aluminum
• Easy menu navigation
• TIG torch has a built in LED light
• Durable yet lightweight foot pedal includes a hook for portability

And a couple negatives:

• Torch heads only work with the Fronius torch
• Foot pedal can be sensitive
• The $6,271 price tag may be high for some

Specifications

• Primary Voltage: 230V
• Lead cord length: 26ft
• Maximum output: 230 amps
• TIG welding output: 10 min/40°C (104°F) 35% D.C.; 10 min/40°C (104°F) 60% D.C.; 10 min/40°C (104°F) 100% D.C.
• Weight: 36.4 pounds
• Machine dimensions: H 14.5 in x W 8.3 in x L 22 in

A few factors to consider before purchasing your TIG welder

Under what conditions will you be working?

Let's say you own a small shop TIG welding aluminum, but you also take on the occasional outdoor maintenance job. A multi-process machine that has TIG and Stick capabilities could serve you better than one that does TIG welding exclusively.

What type of welding projects will you be doing?         

Keep in mind that the material thickness will determine the amps you will need to weld it. The rule of thumb is that you will need one amp of output for every .001" of metal thickness. Also, consider not all the welding machines listed here have dual voltage (120/240). If you are welding at home, a machine with only 240V will require electrical upgrades.

Remember to check the duty cycle before you buy. The maximum duty cycle tells you the percentage of time in 10 minutes that you can operate the welder at a specific amperage continuously before it overheats.

What is your budget?

While the price of the welding machine will always be a consideration, also think about the features and warranty you are getting for your money.

Should I buy a multi-process machine over one that is TIG only?

Hobby users or home users will likely find the flexibility of a multi-process machine more useful. Likewise, professional fabricators normally prefer a multi-process machine in most industrial applications. However, this isn't the case with TIG welding. Companies that exclusively TIG or have exclusive TIG departments typically want a TIG only machine.

Where to buy?

Many welding equipment and supply shops like RedBallOxygen.com offer a selection of welders through their online store or through a special technical welding department.

Learn how to beat inefficiencies, save time and money, and demo equipment for your fabrication shop. With a personalized assessment, you can get actionable insights on how to improve your process and operation with little downtime.

Disclaimer: Some equipment mentioned may be listed for sale through a vendor partnership. All opinions and reviews are our own.