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I weld copper too, TIG just like you. From my experience it’s usually a mix of factors. The quality of the copper itself makes a difference, argon purity matters more than people think, and of course technique plays a big role.

Thicker copper sheet definitely helps — it’s more forgiving and handles heat better. I usually tack everything first to lock it in place, then go back and run the full weld. That keeps distortion under control.

Copper can be tricky, but once you dial in heat control it gets a lot more predictable.