As with all the other TIG consumables, TIG filler rods come in a variety of materials, sizes and specifications.
Here are the common material groups:
Each of the TIG wire material groups listed above can have a variety of different alloy ‘sub groups’ listed, tailored to specific uses. Don’t get bogged down by all the different types. You can spend hours examining the different properties of each one (unless of course, you’re welding something very specific).
Having said that though, their are some key differences which I will try and set out below:
For instance, mild steel may come with a reference A15 or A18…
Welding – What TIG Wire Should I Use? | ||||
---|---|---|---|---|
Material | Type of Welding Wire1 | |||
Type | Code | Composition | Notes | |
Steel | A15 | ER70-S2 | Mild steel (copper coated) | Doesn’t flow as easy. More ductile. Designed for inert gas such as argon (as used with TIG)2 |
A18 | ER70-S6 | Mild steel (copper coated) | Flows better and gives a better appearance. Not as ductile. Originally designed for mixed gas or CO2 (as used with MIG).2 | |
Stainless Steel | Austenitic 300 series | ER308L | One of the most common. | |
ER309L | Dissimilar metals. | |||
ER316L | Chemical equipment and marine. | |||
Aluminiun Alloys | 5000 series alloys | ER4043 | 5% Silicon | Typically covers automotive components and bicycle frames. Most casting alloys |
5000 or 6000 series alloys | ER5356 | 5% magnesium. | Cast and wrought aluminum alloys. More ductile, higher shear strength | |
Chromoly | A15 | ER70-S2 | Mild steel (copper coated) | More ductile. |
ER80S-D2 | Higher strength. | |||
Cast Iron | Ferro-Nickel | NiFe | Typically 53% Iron and 47% Nickel. | Cheaper. Great for welding cast iron. More difficult to machine. |
Pure Nickel | Ni | Typically 99% Nickel. | More expensive. Provides a more malleable weld for machining. | |
Nickel Alloy | ENi-CI | Typically 94% Nickel, 1.5% Carbon, 3% Iron. | Used for joining ordinary gray irons to themselves, or to other ferrous and non-ferrous materials. | |
Copper & Copper Alloys | Silicon Bronze | ERCuSi | Typically 92% Copper, 4% Silicon, 1.5% Manganese, Silicon, 1% Zinc, 1% Tin | For joining dissimilar metals. Stronger joint & less expensive. |
Deoxidized Copper | ERCu | Typically 98% Copper, 1% Tin, 0.5% Silicon. | For welding copper & galvanized steel. More expensive | |
Nickel | Pure Nickel | Ni | Typically 99% Nickel. |
If you’re unfamiliar with purchasing filler wire, it’s good to visualise what you’re going to get. The table below gives a rough guide on how many TIG rods you may get in a pack (by weight):
TIG Welding – Number of Rods by Weight | ||||
---|---|---|---|---|
Material | Size | Contents1 | ||
mm | Inch | 1KG | 5KG | |
Steel & Stainless Steel | 1.00 | 3/64 | 165 | 825 |
1.60 | 1/16 | 65 | 325 | |
2.40 | 3/32 | 28 | 140 | |
3.20 | 1/8 | 18 | 90 | |
4.00 | 5/32 | |||
4.80 | 3/16 | |||
1KG | 2.5KG | |||
Aluminium2 | 1.60 | 1/16 | 190 | 475 |
2.40 | 3/32 | 84 | 200 | |
3.20 | 1/8 | 46 | 115 | |
4.00 | 5/32 | |||
4.80 | 3/16 |
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