Why Tungsten Matters

Your tungsten electrode is what creates and maintains the arc in TIG welding. The wrong tungsten — or a badly prepared one — leads to arc wander, contamination, and inconsistent welds. Getting this right is one of the fastest ways to improve your TIG quality.

Tungsten Types

Pure Tungsten (Green band)

Used almost exclusively for AC welding on aluminum. Forms a balled tip when properly heated. Avoid using it on DC — it doesn't handle the heat as well as alloyed tungstens.

2% Thoriated (Red band)

The most common choice for DC welding on steel and stainless. Handles heat extremely well and holds a sharp point. Note: thorium is mildly radioactive — always grind in a ventilated area and dispose of grinding dust properly.

Ceriated (Grey band)

A popular alternative to thoriated — no radioactivity concerns. Works on both AC and DC, great all-around choice for shops that weld a variety of materials.

Lanthanated (Gold band)

Excellent arc starting and stability on both AC and DC. Lasts longer than thoriated and is considered the best all-purpose tungsten by many professional TIG welders.

Preparation by Application

DC (Steel, Stainless, Titanium)

Grind to a point. The angle matters — a longer taper (2.5x the diameter) gives a more focused arc for thin material. A shorter taper gives a wider arc for thicker material. Always grind longitudinally (along the length), never radially — radial grinding creates seams that cause arc wander.

AC (Aluminum)

Start with a balled or blunt tip. When you strike the arc, the end will ball up naturally from the heat. If it doesn't ball, you may be using the wrong tungsten type.

Sizing Guide

  • 1/16" (1.6mm): Up to 90A — thin material, sheet metal
  • 3/32" (2.4mm): 90–225A — most general fabrication work
  • 1/8" (3.2mm): 200–400A — thick plate, heavy aluminum

The Golden Rule

Re-grind after every contamination. A contaminated tungsten causes an erratic, wandering arc that ruins welds and frustrates welders. Keep a dedicated grinder wheel for tungsten — sharing with steel will contaminate it.