The Reason of Excessive Tungsten Consumption

In order to create an arc and transfer the welding current to the base material being welded, TIG welding requires the use of a tungsten electrode. Tungsten is a non-consumable electrode that has the highest melting point of any metal (3,410 degrees Celsius or 6,170 degrees Fahrenheit). So in theory it can’t melt, right? Wrong.

One of the most common tungsten troubles is excessive consumption. On AC (alternating current) applications, such as TIG welding aluminum, setting the balance control toward the electrode positive (EP) provides good cleaning action (removal of oxides) around the weld. However, it can also cause the tungsten to melt. The best remedy is to set the balance control toward the electrode negative (EN), as this increases the amount of heat going into the work piece as opposed to the tungsten. Seventy to eighty percent toward the electrode negative is a good range. When TIG welding materials like steel, stainless steel, inconel or other ferrous materials using DC (direct current), also set the power source to the electrode negative mode.

Another cause of excessive tungsten consumption is using too high of amperage for a given diameter of tungsten, regardless of whether it is on an AC or DC application. Always follow the tungsten manufacturer’s recommended operating parameters for the diameter being used.

Finally, incorrect or contaminated shielding gas and loose or cracked hose fittings can all cause excessive tungsten consumption. Take care to use clean, pure Argon and be certain all hoses are intact and fittings are tightened prior to welding.

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