Tungsten rods are a rare hard piece of metals which gets mined as tungsten ore. The metals are used for creating a wide array of alloys. Tungsten rod is incredible due to its high melting point and robustness when compared to other rods. Note that tungsten electrodes have a higher density. They are applied in several areas such as:
- Incandescent light bulb
filaments - Cathodes in the welding process
- x-ray tubes
- radiation shielding
- military applications
- superalloys
Tungsten in welding
Tungsten rod is
used in welding works due to its higher melting point of up to 6192ºF or
3422ºC. The metal is characterized by a high melting point when compared to
other metals. The tungsten products are fabricated by drawing, extruding, sintering,
or by forging.
A high-quality
electrode should have adequate quantity and evenly distributed oxides
throughout the electrode. The best quality tungsten material guarantees
superiority and consistency in the welding process and performance.
The Common Types of electrodes
The amperage,
diameter, and composition
of the electrode are based on the dimension and type of the material to
be welded. Below are the main types of tungsten electrodes.
a. Electric-type W Green
- These electrodes don’t contain oxides
- Have a low arc starting capacity
- Poor amperage capacity and electrode life
- Good environmental characteristics
- It is mainly used in TIG
b. Electrode
type WC20 grey
- Features an oxide of 1.8-2.2 %
- Have a good amperage capacity
and electrode life - They are environmentally
friendly since they are radiation free - They are mainly used in plasma
welding, TIG welding,
plasma spraying, and plasma cutting - They are utilized for materials
such as acid, rust, and heat resistant steel - Can be used in Direct Current only
- The application of the ceriated
electrode avoids radiation issues. For this reason, it has the best welding
characteristics that can’t cause harm to the environment and people
c. Electrode type WL10 –black
- It has an average arc starting
and can’t be used in plasma welding because of the auxiliary arc - Mainly used in plasma cutting,
plasma welding, keyhole plasma welding, and plasma spraying - It uses both DC and AC currents
- These Electrode types are used
in several applications such as joining technology for reedy plate high alloy
steel, forging dies, aluminum cutting resurface valve welding, and plasma
spraying of carbide, oxide, AI powder and nitride
d. Electrode type WZ8 white
- Has a better arc starting,
amperage capacity and electrode life - Works on AC only
- Used in TIG welding works
- Works well on metals such as
nickel and nickel alloys, aluminum and aluminum alloys, magnesium and magnesium
alloys, aluminum bronze
Once you have
purchased a high-quality TIG welding equipment for your detailed projects, you
will need to pick the bestrode. Whether you want to use DC or AC process for
your welding project, here is a guide to help you buy the right TIG rods,
comprising new tungsten rods that might be new to you.
Picking the correct color of the tungsten rod for the welding project
Each TIG rod
comes with a unique color classification, which makes them be identified
easily. Depending on electrode properties, welding professionals will get particular
usefulness and applications that might work well for the specific rod. Types of
electrodes include:
a. Green TIG welding rods
These are unalloyed
tungsten rods that are primarily utilized for AC process in welding of
magnesium and aluminum materials. They are widely used since they are affordable.
Nevertheless, they tend to burn up faster than other alloy rods, so make sure you have many of
them if you choose this type.
Many welders
love using the unalloyed tungsten rods because they are perfect on the AC sine tendency
welding process. They also make a hard, balled tip that leads to a steady arc.
Apart from having a high rate of consumption, the rods do not start well as
ceriated or thoriated electrodes.
b. Red thoriated electrodes
These are one of
the most used electrodes since the two percent thorium combined with tungsten
makes it versatile and durable. Welding professionals can drudge the tip of the
electrodes to make a sharp edge to get a stable and long lasting arc. The finishing
weld slick is clean because the electrodes produce fewer residues and thorium
lets the electrode to have an easy arc start and high current carrying ability.
These TIG rods
allow you to switch between DC
and AC welding process. Welders use the thoriated electrodes on works
that involve thin aluminum, carbon steel, titanium nickel, and stainless steel.
However, welders should be cautious when using thorium electrodes since they
are radioactive.
c. Orange ceriated electrodes
These electrodes
have 2% ceriated material. They are perfect for direct current welding and low
current applications. Because they can weld stainless steel, carbon steel,
titanium, and nickel alloys, many welders have realized that it can work
perfectly in place of thoriated rods.
Experts don’t
recommend the ceriated electrode for welding projects at high amps because the temperature
can affect the properties
of the rod. Welding professionals like to use the ceriated rods at low
temperatures for tiny, precise parts, welding a thin piece of metals and pipe
fabricating.
d. Gold lanthanated rods
These TID
electrodes worked well in DC and AC settings because the rods are balled or
sharpened correspondingly based on the welding project. They can weld metal from
square wave energy source, and they provide great arc stability and arc start.
Because of their
versatility and durability, most welders prefer to use lanthanated as a
substitute for the thoriated electrode. They are also nonradioactive components
in the steel.
e. Brown zirconiated electrodes
These electrodes
have less quantity of zirconium and are ideal for AC fabrication projects.
Because zirconium us a hard metal that is resistant to cracking, it offers a steady
arc and resistant to contamination. It also has the same amperage current like
that of thoriated electrodes.
TIG (Tungsten
Inert Gas) welding is a famous form of welding that uses tungsten electrodes to
join different metals. Note that the tungsten electrode is created from tungsten rods, and they are
essential in the welding process since they channel the current needed to form
an arc. So, make sure you choose the right electrode.
