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.
There are many parameters you need to consider when buying TIG consumables.
TIG Welding 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
This is only a guide, please refer to the manufacturers data sheets.
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.
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.
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