Selecting the right Tungsten electrode is crucial for achieving a stable arc, good penetration, and high-quality welds in TIG (Gas Tungsten Arc Welding – GTAW). The right choice depends on the material type, current type (AC/DC), and welding application.
1. Consider the Type of Metal Being Welded
Different metals require specific tungsten compositions for optimal performance.
| Metal Type | Recommended Tungsten | Tungsten Color Code |
|---|---|---|
| Mild Steel & Stainless Steel | 2% Thoriated (WT-20) | 🔴 Red |
| Thin Metals (Stainless, Titanium, etc.) | 2% Ceriated (WC-20) | ⚪ Gray |
| Aluminum & Magnesium (AC Welding) | Pure Tungsten (WP) or 2% Lanthanated (WL-20) | 🟢 Green / 🔵 Blue |
| All-Purpose (AC/DC Welding) | 2% Lanthanated (WL-20) or 1.5% Lanthanated (WL-15) | 🔵 Blue / 🟡 Gold |
| High-Amperage AC Welding (Aluminum, Magnesium) | Zirconiated (WZ-8) | ⚪ White |
2. Understand Tungsten Types and Their Uses
Each tungsten type has unique properties that make it suitable for different applications:
| Tungsten Type | Composition | Best For |
|---|---|---|
| Pure Tungsten (WP) – Green | 99.5% Tungsten | AC Welding (Aluminum, Magnesium) – Ball tip for stability |
| 2% Thoriated (WT-20) – Red | 98% Tungsten, 2% Thorium | Best for DC welding steel, stainless steel, titanium |
| 2% Ceriated (WC-20) – Gray | 98% Tungsten, 2% Cerium | Low-amperage DC welding, good for thin materials |
| 1.5% Lanthanated (WL-15) – Gold | 98.5% Tungsten, 1.5% Lanthanum | Versatile for AC & DC welding, long-lasting |
| 2% Lanthanated (WL-20) – Blue | 98% Tungsten, 2% Lanthanum | Excellent arc stability, best all-purpose choice |
| Zirconiated (WZ-8) – White | 98% Tungsten, 0.8% Zirconium | High-amperage AC welding, great for aluminum |
3. Match Tungsten Size to Amperage
The tungsten diameter must match the welding amperage range for proper arc stability.
| Tungsten Diameter | DC Amperage Range | AC Amperage Range |
|---|---|---|
| .040" (1.0mm) | 1 - 20A | 5 - 15A |
| 1/16" (1.6mm) | 10 - 90A | 20 - 100A |
| 3/32" (2.4mm) | 80 - 200A | 100 - 250A |
| 1/8" (3.2mm) | 150 - 300A | 200 - 375A |
| 5/32" (4.0mm) | 200 - 400A | 300 - 500A |
✅ Thin metal welding → Use smaller tungsten (e.g., 1/16")
✅ Thicker metal welding → Use larger tungsten (e.g., 1/8")
4. Tungsten Tip Preparation
- DC Welding (Steel, Stainless, Titanium) → Sharpened Tip for focused arc.
- AC Welding (Aluminum, Magnesium) → Ball Tip for better arc stability.
- All-Purpose (Lanthanated, Ceriated) → Sharpened tip for both AC/DC.
5. Best All-Around Choice for Most Welders
If you want one tungsten type that works for both AC & DC welding, 2% Lanthanated (WL-20 – Blue) is the best option. It provides:
✅ Excellent arc stability
✅ Long electrode life
✅ Suitable for steel, stainless, aluminum, and titanium
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