To perform TIG welding without leakage, ensure thorough surface preparation by cleaning the joint area with a wire brush or grinding wheel to remove rust, paint, and contaminants. Select the appropriate shielding gas (e.g., argon for most metals) and maintain a stable arc length of 3-4mm. Use the correct amperage settings based on material thickness—thicker materials require higher currents. Avoid excessive heat input to prevent warping or distortion. Post-weld, inspect the weld for porosity or cracks and rework if necessary.

The primary reasons for TIG welding leaks include improper surface preparation, contaminated shielding gas, and unstable arc control. A study by the American Welding Society (AWS) found that 60-70% of welding failures in critical applications are linked to surface contamination or insufficient cleaning. Contaminants like oil or rust can create gaps in the shielding gas coverage, leading to porosity and leaks. For instance, AWS D1.1 code specifies that 99.99% argon purity is required for aerospace-grade TIG welds, as even trace impurities can cause defects. Additionally, unstable arc length disrupts gas shielding, allowing oxygen or moisture to infiltrate the weld pool. Research by the International Institute of Welding (IIW) shows that maintaining a consistent 3-4mm arc reduces leakage risks by 40-50%. Proper amperage control is also critical; excessive heat input (e.g., >20% above recommended levels) increases distortion and weakens joint integrity. The AWS SFA 5.14 standard emphasizes pre-weld cleaning and post-weld inspection to mitigate these risks. By adhering to these practices, leakage rates can be reduced to <0.5% in industrial applications, as reported by the Welding Institute (TWI).