WINNING PREPARATION

by Jim Elizarraz, president, Diamond Ground Products

Proper preparation of tungsten electrodes for

X
arc welding begins with the fundamentals

X
 A great tungsten welding electrode is a
lot like a great NFL quarterback. While

A
there is no shortage of variables in their
surroundings, the ones that perform
best will always focus on fundamentals
and consistency.

30

Three fundamental considerations

for the preparation of tungsten Tungsten electrode geometry.
electrodes – electrode geometry,
electrode preparation equipment and
electrode preparation techniques – will
help ensure that a welder is more like
Tom Brady and less like Ryan Mallett.

Electrode geometry
Geometry choices affect key tungsten
attributes, such as electrode life, ease

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 of arc starting, weld penetration and
arc shape. Clearly, it is a critical process
variable that should be tested to
create the optimum geometry for a
welding application. Once optimized,
it is essential to maintain the strictest
tolerances for all subsequent welds.
Electrode diameter: Choosing
the electrode diameter is often an
attempt to maximize arc starting and
tungsten life, two aspects that tend
to work against each other. Welders
31 should always begin by consulting the
welding equipment manufacturer’s
recommendations, but testing to see
what works best is an extra step that all
great welders should take.
A small diameter is easier to arc For the best possible
start, but may deteriorate quickly arc stability,
and there is increased probability of diamond grinding of
particles contaminating the weld. A tungsten electrodes
large diameter accommodates higher should be done with
amperages and lasts longer but may the length of the
have difficulty arc starting and may electrode at a 90°
have arc instability if amperages are not angle to the axis of
high enough. the grinding wheel.
Electrode included angle (taper): DC
welding electrodes should be ground
longitudinally and concentrically to
an included angle with a dedicated The single most important aspect of proper
diamond grinding wheel. Different electrode grinding is that the grind be done
angles produce different arc shapes longitudinally.

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 Correct = lengthwise grind
and offer different weld penetration and changes in arc shape from one
marks do not restrict current.
32 capabilities.
Blunt electrodes (large included
Incorrect = crosswise grind
electrode to another.
marks restrict welding
angle) last longer, have better weld Electrode prep equipment
current, cause arc wander
penetration, have a narrower arc A dedicated tungsten electrode
and risk inclusions.
shape and can handle more amperage grinder is essential for creating
without eroding. Sharp electrodes the highest quality tungsten
(small included angle) offer less arc electrodes consistently. Standard
weld, have a wider arc and have a more bench-type grinders or Dremel
consistent arc. modifications do not offer the ability
Electrode tip (flat): The shape of the to grind longitudinally or provide
tungsten electrode tip is important any guarantee of consistency from
in precision arc welding because as electrode to electrode. In addition, a
the flat size increases, so does the non-dedicated grinder contaminates
chance of arc wander and starting the electrode with foreign material
difficulty. However, increasing the flat that compromises weld quality in a
also improves weld penetration and number of ways.
increases electrode life. For efficient production of
An incorrect or inconsistent flat can consistent and repeatable electrodes
cause pointed electrode tips to drop and welds, consider the following
into the weld pool. It also can result in characteristics in a dedicated tungsten
arc instability, reduced electrode life electrode grinder:

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2% Thoriated Tungsten has been the welding industry standard
for decades. Now, some tungsten suppliers will have you believe
it won’t be around much longer!

The Tungsten Electrode Experts™ at Diamond Ground Products

have 2% Thoriated in stock and readily available with no end in
sight. Anybody telling you otherwise is just trying to break up a
great relationship.

Call DGP today to get your 2% Thoriated

Tungsten or to get a FREE sample of our
other tungsten varieties such as Tri-Mix™,
Cryo-T and more.

It’s ok to look, we won’t tell.

 • Longitudinal grinding create jagged edges, imperfections or proper electrode grinding is that the against the grain.
• Diamond grinding wheel poor surface finishes that contribute to grind be done longitudinally. Tungsten Additionally, electrons flow at a greater
• 20 Ra finish (or better) welding inconsistency and defects. electrode manufacturing is done with the density on the surface of the electrode.
• Measured cutting tool Electrode included angle (taper) prep: molecular structure of the grain running If electrodes are ground or polished
• Dust collection The single most important aspect of lengthwise. Grinding crosswise is grinding crosswise, the electrons have to jump
• Minimal variation in tolerances
• Ease of use, setup and
modification

While some may argue the cost of

a dedicated grinder is prohibitive, it’s
not nearly as expensive as the cost of
34 welder downtime, rewelding of bad
parts, cost of scrapped materials and
safety of welding staff.

Electrode prep techniques

The tungsten electrode is the crucial
carrier in the welding process and must be
ground and cut properly. An improperly
prepared electrode leads to arc wander,
splitting, shedding, and inconsistencies or
expensive mistakes in the form of material
waste. Properly ground and cut electrodes
improve arc starting, stability and all- To recondition an electrode that has minimal
around welder productivity. contamination, either new or cut off, place
Diamond wheels are recommended the electrode at an exact 90° angle to the
for all tungsten electrode grinding and side of the grinding wheel.
cutting. While tungsten is a very hard
material, the surface of a diamond wheel
is harder, which makes for a smooth grind.
Grinding with other types of wheels can

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 across the grinding marks. The arc tungsten incorrectly using one of the
begins before the tip, spreads out and following methods:
often wanders. The tungsten electrode
becomes overheated and wears out • Breaking the electrode manually or
more quickly. Longitudinal grinding with wire cutters
allows an arc to start straight and remain • Twisting the electrode with two
stable and concentrated. pairs of pliers
A diamond grinding wheel should • Notching the electrode on the
not be used for grinding anything other grinding wheel and then breaking it
than tungsten. This will help ensure the The best way to ensure that by hand or with a hammer or pliers
wheel and tungsten tip do not become all contamination is removed • Hitting the electrode with a
contaminated during the grinding from the tip is to cut off that hammer on a sharp metal edge
35 operation and do not transfer foreign part of tungsten.
material to the weld. All of these methods can cause
The smoothness of the finish on the safety and weld problems. The
prepared tip of the tungsten electrode point and causing erosion. However, angle to the side of the grinding wheel. tungsten electrode can splinter or
determines some of the characteristics for welding power supplies that do not Cutting electrodes to length: A shatter unnoticeably, which can cause
of the welding process. In general, points have strong arc-starting characteristics, contaminated electrode produces arc instability and weld defects as
should be ground as fine as possible to a finish of about 20 Ra is better because an erratic arc and a contaminated well as the risk of eye or hand injury.
improve welding properties and increase longitudinally ground lines help steadily weld. The best way to ensure that It is much easier to cut an electrode
the electrode life. Electrodes that are lead electrons to the extreme point of the all contamination is removed from quickly and properly with the correct
ground too coarse result in unstable arcs. electrode, which assists in arc starting. the tip is to cut off that part of cutting tool designed specifically for
A standard finish of approximately Electrode tip (flat) prep: Depending tungsten. Grinding the tip when it is the hard and brittle tungsten.
20 roughness average (Ra), which would on the welding process, flat preparation contaminated may not remove all of Using a diamond cutting wheel
still show the longitudinally ground might be on a new tungsten electrode the contamination and will deposit helps ensure that the cut is clean
lines to the naked eye, is an all-purpose, or a previously used electrode. If the the contamination on the grinding and smooth and void of fractures or
quality finish for any application. A end of a used electrode is extremely wheel, only to be picked up again in splintering. The tool should be quick
high-polished, mirror-like finish of 6 contaminated, it should be removed future grinding. and easy to use, have safety covers
to 8 Ra, in which few or no lines can be before flat preparation. To recondition Because tungsten is a very hard and provide a scale to ensure the
seen, is better for the longevity of the an electrode that has minimal material, proper cutting involves using exact length is measured and cut.
electrode because it reduces the risk of contamination, either new or cut off, a diamond cutting wheel for consistent,
contamination “sticking” to the electrode place the electrode at an exact 90° clean cuts. Many welders cut their Diamond Ground Products

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