TIG Welding Consumables

TIG welding consumables come in a variety of types and sizes, dependant on the material you want to weld and it’s size. The consumables also come in three distinct groups.

• Filler Wire (or Rods).
• TIG Torch Parts and Accessories.
• Shielding Gas.

The consumables must also fit the type of TIG torch you’re using.

Topics on this Page:

• TIG Welding Consumables (General Information):
• Topics (In More Detail):
• Further Information:
• Image Gallery:

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TIG Welding Consumables (General Information):

There are many parameters you need to consider when buying TIG consumables.

• The type of material(s) to be welded.
• The thickness of the material to be welded.
• The filler rods and their compatibility.
• The type of welded joint.
• The different variations of the interchangeable ‘consumable’ parts (and do they fit the torch?).

TIG Welding – Gun Part Sizes (A Rough Guide):

TIG Welding – Consumable Cross Reference Guide1
Material Thickness			Amps		Size (mm)
mm	Inch	Gauge	DC	AC	Filler Rod	Tungsten	Gas Cup
0.50	1/64	24	5-20	5-15	1.02	1-1.6	3-5
0.65	1/32	22	10-35	10-30	1.02	1-1.6	3-5
0.80	1/32	20	20-50	25-45	1.02	1-1.6	4-5
1.00	3/64	18	25-80	45-60	1.0	1-1.6	4-5
1.30	3/64	16	40-90	50-100	1.0	1.6	4-6
1.60	1/16	14	60-100	50-100	1.6	1.6	4-6
2.40	3/32	11	85-125	90-150	1.6-2.4	1.6	4-6
3.20	1/8		100-135	125-190	1.6-2.4	2.4	4-6
4.00	5/32		125-175	180-200	2.4	2.4	5-7
4.80	3/16		150-225	180-240	3.2	2.4	7-8

Reference:

• ¹ Due to the many different parameters (the type of material, its size, the type of joint, etc, etc), the table above should be considered as a very rough guide:
• ² Tig filler rods are generally sold in sizes from 1.0mm and upwards (aluminium 1.6mm). If you want a smaller size wire, MIG wire is often used.

Notes:

• Always follow the manufacturer’s warnings, instructions, and their Material Safety Data Sheet (MSDS). Welding fumes and dust can affect your health.

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Topics (In More Detail):

The topics listed below, will hopefully make it easier to understand what the differences are between the various TIG welding consumables, and make it easier to obtain the correct items for the job in hand.

The three distinct groups of TIG consumables:

1. TIG Filler Wire (or Rods):

• TIG Filler Rods (or Filler Wire):

2. TIG Torch Parts and Accessories (Consumables):

• Back Caps:
• Collets:
• Gas Cup (Ceramic and others):
• Gas Nozzle (or Gas Lens):
• Heat Shield (or Insulator):
• O’Rings:
• Tungsten Electrodes:

3. TIG Shielding Gas:

• Shielding Gas:

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Further Information:

What consumables fit my TIG torch?

• TIG Gun (Torch) – The Different Types:

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Image Gallery:

– click or tap the image to view full size –