Getting started with TIG welding is full of new things to learn, even for an otherwise experienced welder. Between all the functions and settings, there’s a lot to learn. And then there’s these things called the “TIG welder consumables,” those things your welder will use up in order to operate effectively. Understanding the role of each of these is critical to mastering your new tool.
Consumables like the electrodes, gas nozzles, and filler rod wear out over time, and knowing when to replace them is essential to producing clean, quality welds. There’s nothing worse than having to stop your job because something is worn or used up. To avoid this, keep a supply of the correct consumables on hand. They’re often sold in pre-sorted kits with everything you’ll need.
This article will explain exactly what the key consumables in a typical TIG welder are, what exactly is “consumed” over time, and how to recognize when they’ve reached the end of their life.
TIG Welder Consumables
1 – Filler Rod
The most essential consumable in TIG welding is the filler rod, sometimes called TIG filler. The filler rod is used to add material to the weld pool to fill the joint between the workpieces.
What wears out – The filler rod is consumed as it’s melted into the weld pool.
Symptoms of wear
- The filler rod wears down as it’s consumed during welding. You’ll simply notice it getting shorter over time.
2 – Tungsten Cup or Gas Nozzle
The gas nozzle directs the shielding gas more efficiently around the weld pool, improving the gas coverage and preventing oxidation of the weld. These can be either ceramic or clear glass (Pyrex) for improved weld visibility.
What wears out – Over time, the tungsten cup can become damaged, cracked, or clogged, reducing its effectiveness.
Symptoms of wear
- The cup may become physically damaged, leading to decreased gas flow and possible contamination of the weld.
- When the gas lens becomes clogged, it may restrict gas flow and result in poor shielding of the weld.
3 – Tungsten Electrode
The tungsten electrode carries the welding current and produces the arc that melts the base material. It’s a critical part of the welding torch and must be maintained with a sharp point for accuracy. A specialized tungsten grinder makes easy, clean work of maintaining the tip.
What wears out – The tungsten electrode wears out as it degrades from the intense heat. It may become eroded, contaminated with material, or develop a rounded tip.
Symptoms of Wear
- The tip of the electrode may become smaller or more pointed than the original shape.
- If the electrode is contaminated with base material, the weld quality may degrade.
- The electrode may become unstable, making it harder to maintain a consistent arc.
- A rounded or blunted tip can result in a less focused arc, leading to less precision in the weld.
4 – Diffuser or Gas Lens
The nozzle or gas lens directs the flow of shielding gas around the weld and protects the weld pool from contamination.
What wears out – The nozzle can become clogged, damaged, or worn down, especially if it’s exposed to high heat frequently.
Symptoms of Wear
- A cracked nozzle can lead to improper gas flow, causing poor welds.
- A clogged nozzle will restrict gas flow and cause poor shielding, which may lead to oxidation or other defects in the weld.
5 – Collet
The collet holds the tungsten electrode in place, while the collet body serves as a support for the electrode.
What wears out – Collets can wear out from frequent tightening and loosening, or they may become damaged if the tungsten is inserted incorrectly.
Symptoms of Wear
- If the collet doesn’t hold the tungsten securely, it can lead to an unstable arc.
- Over-tightening or improper handling can lead to cracks in the collet body.
6 – O-Rings
O-rings are used to seal various parts of the TIG torch, such as the nozzle and collet body, ensuring proper gas flow and preventing leaks.
What wears out – O-rings wear out over time from heat and repeated use, especially if they’re exposed to extreme temperatures.
Symptoms of Wear
- Worn-out O-rings can cause leaks, which will result in inconsistent gas flow and poor weld quality.
