Why Is My Tungsten Melting When Welding Aluminum?

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Why do I keep melting my Tungsten?

Tungsten is a non-consumable electrode that has the highest melting point of any metal (3,410 degrees Celsius or 6,170 degrees Fahrenheit). Another cause of excessive tungsten electrode consumption is using too high of amperage for a given diameter of tungsten, regardless of whether it is on an AC or DC application.

What color tungsten do you use for welding aluminum?

Pure Tungsten (Color Code: Green)

Pure tungsten also provides good arc stability for AC sine wave welding, especially on aluminum and magnesium. It is not typically used for DC welding because it does not provide the strong arc starts associated with thoriated or ceriated electrodes.

What is the best tungsten for welding aluminum?

If you are AC TIG welding aluminum for the first time we would suggest using a 2% ceriated in 3/32. Two solid options include Blue Demon or Weldcraft. Ceriated is the most popular choice due to the easy arc start at low amperages.

How do I prevent tungsten contamination and discoloration?

How do I prevent tungsten contamination and discoloration? Allowing the tungsten to touch the weld pool is one of the most common causes of contamination. This problem can be resolved by moving your torch farther away from the workpiece, which in turn lengthens the arc.

What is the melting point of tungsten?


Is purple tungsten good for aluminum?

This rare earth tungsten offers excellent ignition characteristics and consistent welding properties. They are universal and suitable for all applications in the whole range of AC and DC welding of non-alloyed and high-alloyed steel, aluminium, titanium, nickel, copper and magnesium alloys.

Is Lanthanated tungsten good for aluminum?

You can use blue lanthanated tungsten as an all-purpose option with a variety of metals, including nickel alloys, aluminum, cobalt, copper, carbon steels, and titanium.

What is the difference between red and green tungsten?

Color code and what it means

The main colors/varieties of TIG electrodes and their American Welding Society abbreviation are as follows: Green (EWP) = Pure Tungsten, Orange (EWCe-2) = 2% Ceriated, Red (EWTh-2) = 2% Thoriated, Gold (EWLa-1.5) = 1.5% Lanthanated, Brown (EWZr-1) = 1% Zirconiated.

How thick can 200 Amp TIG weld?

A 200-amp unit can weld between 5/16” steel. A 250-amp unit can weld 1/2” steel.

How do you choose tungsten for TIG welding?

Is E3 tungsten good for aluminum?

E3 Electrode Features and Benefits:

Universal and suitable for all applications for DC and AC welding pf non-alloyed and high-alloyed steel, aluminum, titanium, nickel, copper, and magnesium alloys.

Do I need to ball my tungsten for aluminum?

Can you weld aluminum with sharp tungsten?

How do you sharpen tungsten for TIG welding?

Why do my TIG welds look dirty?

Poor gas coverage leads to contamination

The weld here shows contamination caused by lack of shielding gas, which can happen when the shielding gas is not turned on, there is either too little or too much gas shielding, or the gas is blown away.

How do you clean tungsten electrodes?

What can melt tungsten?

The only known element with a higher melting point than tungsten is carbon, at 6422°F (3550°C). However, even carbon cannot be used to hold liquid tungsten, because at high temperatures the two will react to form tungsten carbide.

Why is tungsten melting point so high?

Tungsten has the lowest coefficient of thermal expansion of any pure metal. The low thermal expansion and high melting point and tensile strength of tungsten originate from strong metallic bonds formed between tungsten atoms by the 5d electrons.

What is the melting point of aluminum?


What is the purple tungsten for?

Tungsten electrodes – Purple is the new red

For a long time, the red, thoriated tungsten electrodes were the first choice in TIG welding. In some places they are still considered the best solution for welding with direct current of high-alloy and stainless steels.

What is purple tip tungsten used for?

Rare Earth (Purple) Electrodes

It is the perfect substitute for red thoriated electrodes. They perform well in DC applications and are great for welding copper alloys, nickel alloys, titanium alloys, and stainless steel.

How do you pick tungsten?

What is 2% Lanthanated tungsten used for?

2% Lanthanated (Blue)

Blue electrodes are effective for welding aluminum alloys, magnesium alloys, nickel alloys, copper alloys, titanium alloys, low-alloyed steels, and non-corroding steels.

How do you put TIG on aluminum?

How do I TIG weld aluminum?

How do you prepare tungsten for aluminum?

  • Sharpen one side of the pure-tungsten electrode to a spiky tip using a bench grinder.
  • Put the sharpened electrode aside for 10 minutes, letting it cool down.
  • Sharpen the other edge of the electrode to a point too, exactly like the other end.
  • What tungsten is radioactive?

    The Thorium used in 2% thoriated tungsten is a radioactive element and therefore can be dangerous to the health of those exposed to it and to the environment.

    What is blue tungsten?

    Blue tungsten is a good substitute for thorium oxide. It provides proper arc ignition and is more long-lasting than thoriated electrodes. It can be used for both AC and DC welding with both transformer and inverter power sources.

    Why is undercut considered a cardinal sin in welding?

    Undercut - This is the CARDINAL SIN of welding grasshopper! Cutting into the steel with the force of the arc leaves a cut out groove in the weld. If this is not filled back in with filler metal, it leaves a WELD DEFECT which is a weak point that can cause the joint to fail.

    Is TIG welding as strong as stick?

    The process grants the welder a great deal of control over the weld, allowing for stronger, higher quality welds. TIG welding is also significantly slower than either MIG or stick, and demands that the surface of the workpiece be absolutely immaculate.

    Can I weld Aluminium with DC TIG?

    DC GTAW can work very well on aluminum, so don't be afraid to try it. Just be aware that the technique is different than that used for AC.

    What is the best tungsten for mild steel?

    2% Thoriated Tungsten Electrode. The 2% thoriated (color code red) is an all-purpose tungsten electrode and it's recommended for welding mild steel because they work well on lower temperatures, which is what you need if you don't want the steel to warp.

    How long does a tungsten last?

    On average, tungsten rings last 2-5 years before maintenance is required. However, it can last forever if you take good care of it. You can take it to your local jewelers for cleaning and polishing.

    Why is aluminum welded with AC?

    AC current is used to weld aluminum because its positive half cycle provides a "cleaning" action and its negative half cycle provides penetration. If not removed, the oxide layer can inhibit proper weld fusion and puddle fluidity.

    What color is E3 tungsten?

    3/32 in E3 (purple) Tungsten for TIG Welding.

    What angle do you grind tungsten?

    For the best possible arc stability, diamond grinding of tungsten electrodes should be done with the length of the electrode at a 90° angle to the axis of the grinding wheel. The single most important aspect of proper electrode grinding is that the grind be done longitudinally.

    What gas do you use for TIG welding aluminum?

    Pure argon is the most popular shielding gas and is often used for both gas metal arc and gas tungsten arc welding of aluminum. Mixtures of argon and helium are probably the next common, and pure helium is generally only used for some specialized GTAW applications.

    What Rod do I use for aluminum TIG welding?

    Aluminum Tig Welding Rods

    4043 aluminum tig rod - the most versatile for 3003, 6061, a355 aluminum castings etc. and do yourself a favor and get some 4047 aluminum filler rod for castings where porosity rares its ugly head. 4047 filler rod contains 12% silicon. That makes it flow better, with less porosity.

    How do you Heliarc aluminum?

    How do you set TIG tungsten?

    What end of the tungsten do you sharpen?

    We recommend you flatten or blunt the tip of the tungsten electrode after sharpening. The guideline for this is approx. ten percent of the electrode diameter – an electrode with a diameter of 1.6 mm then has a blunt tip of approx. 0.15 mm.

    Does it matter how you sharpen tungsten?

    How do I prevent tungsten contamination and discoloration? Allowing the tungsten to touch the weld pool is one of the most common causes of contamination. This problem can be resolved by moving your torch farther away from the workpiece, which in turn lengthens the arc.

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