Weld Like a Pro

Grinding Tungsten
Electrodes with
Diamond Wheels

An ARC-ZONE.COM
Product Tip Guide

02-10-2022

GeneralMIG/GMAW

TIG/GTAW

Stick/SMAW

PlasmaGeneral/Multiprocess

Introduction
We began supplying tungsten electrode grinders when we discovered our customers were frustrated
by the industry-wide lack of quality machines, technical information, and technical support. We
found the market had many companies offering electrode grinders—each selling its own machinewith little regard for specific customer needs. To redress that, we offer the industry’s widest rangeof tungsten grinding machines along with unparalleled instructional data and technical support.
View our complete line on www. arc-zone.com.
For TIG/GTAW (Tungsten Inert Gas arc welding/Gas Tungsten Arc Welding) and PAW (Plasma ArcWelding), there is no better way to prepare a tungsten electrode than with a diamond grinding
wheel. A diamond-ground tungsten electrode delivers a cleaner, more precise, and consistent weld
than the same electrode ground with a bench grinder, belt sander, side grinder, or any other nondiamond wheel.

Dry or Wet Grinding
You can diamond grind electrodes either wet or dry. Both have benefits and drawbacks.
Dry Grinding
Dry tungsten is the most common type of grinder—the machines are simple to build and deliver aconsistent finish. You can change wheel grits to achieve a specific grinding rate—the coarser thediamond grit, the faster the grind. For a smooth finish, grind with a 300-grit wheel, the standard
on most dry grinders. For small-diameter tungsten grinding, 1/16” (1.6 mm) or below, use a finer
grit wheel for that critical smooth-ground finish.
Wet Grinding
Wet or liquid tungsten grinders are more specialized and technically advanced machines. Wetgrinding delivers a near polished tungsten finish—the most desirable finish in terms of arc startingand electrode life. Additionally, wet grinders don’t allow the tungsten material to overheat during
grinding—a common problem for dry grinders that can change the oxide structure of the tungsten.
Fully enclosed, wet grinders are by far the best solution for operator safety and dust management.

Types of Diamond Wheels
Diamond grinding wheels come in a variety of shapes and sizes. Their surface binding processdepends on their intended host grinder. Electroplated and resin-bonded wheels are the mostcommon.

Arc-Zone.com, Inc. • 1331 Specialty Dr • Vista, CA 92081 • Tel. 1.760.931.1500
Email: info@arc-zone.com

Resin-Bonded
Resin bonded wheels are designed for cutting or grinding tungsten on the rim or top (narrow side)of the grinding wheel. The resin bonding process offers good longevity because it produces a thickrim, though its sides have low lateral strength.
The resin bonding process starts with a core or wheel blank. From there, the wheel’s bonding iscleaned. The diamond grinding media is then mixed with the resin and coated onto the wheel
blank. The wheel is then inserted into a heated mold under tons of hydraulic pressure. That
pressure removes bubbles or gaps in the diamond grinding media and bonds it to the wheel.
ElectroplatedElectroplated diamond grinding wheels are best for tungsten grinders using the front or face (wideside) of the grinding wheel to prepare electrodes. Rather than using a glue to bond the grinding
media to a wheel, this process uses metal plating. Typically, the wheel core is plated with a nickel
base in a plating tank. During that process, the nickel captures suspended grinding material,bringing it along when it plates the wheel.

Diamond Wheel Finishes
Nickel Plate
Nickel plated wheels appear shiny, sometimes with a yellowish chrome-like finish. They arecommonly used throughout the industry.
Corrosion Resistant Paint
Some wheels, especially wet grinding wheels, are painted to resist corrosion. Generally, they areresin bonded with a wheel made of aluminum. They are either green or black.

Wheel Media Grits
Grit is the actual composition of the diamond grinding surface—the diamond media that removes
the material from the tungsten electrode.
100—Heavy Coarse Grit
Grinds large-diameter, 3/16” (4.8mm) or larger, tungsten electrodes. This grit quickly removes
material.
150—Coarse Grit
Grinds large-diameter , 1/8” (3.2mm) or larger, tungsten electrodes. This grit removes material
quickly, but not as quick as heavy coarse grit. It is often used to dress an electrode for a subsequent
grinding with a finer grit wheel.
300—Medium Grit
Grinds nearly all tungsten electrodes using an all-purpose wheel, which is why this grit is often thedefault on wheels that come with the grinder. It provides a smooth finish and moderately quick
material removal.

Arc-Zone.com, Inc. • 1331 Specialty Dr • Vista, CA 92081 • Tel. 1.760.931.1500
Email: info@arc-zone.com

400—Fine Grit
Grinds small diameter tungsten electrodes—1/16” (1.6mm), .040” (1.0mm), and .020” (0.5mm).
This specialized grit provides a smooth finish and usually isn’t used for other purposes.
600—Super Fine Grit
Grinds small diameter tungsten electrodes—1/16” (1.6mm), .040” (1.0mm), and .020” (0.5mm).
This specialized grit provides a very smooth near-polished finish.

Maximizing Wheel Life
Diamond-ground tungsten electrodes are widely used in TIG/GTAW and PAW. To get the best
performance from a tungsten grinder—lowering operating costs, improving productivity, andmaximizing weld quality—we recommend that you follow these simple steps:
1. Remove contaminated sections from the tungsten electrodes before grinding. Cut the electrodeoff just beyond the contaminated area. The tungsten should be clear of any discoloration orforeign materials.
2. Grind tungsten slowly and consistently, smoothly rotating the electrode as it contacts thewheel.
3. Don’t overheat the electrode. If the electrode becomes red hot, it can cause the added dopiants(helpful added chemicals) to migrate to the tip and evaporate, leaving you with a pure tungsten
electrode.
4. Don’t jam the electrode into the wheel. Instead, apply slight, consistent pressure.
5. Start grinding on the outermost edge of the diamond grinding wheel. As the wheel wears,grinding time increases and grind quality deteriorates. To minimize this, change the electrode’s
contact point on the wheel to use a new spot with unused diamond media.
6. If your wheels are double sided, for added life, be sure to reverse the wheel and repeat theprocess.
7. Contact the Tungsten Grinding Experts™ at Arc-Zone.com for tips on which diamond grinding
wheel is best for your machine and application.
No matter what type of grinder you choose, consider the replacement cost of the diamond wheels,
which can be expensive—sometimes $300 or more (depending on the machine). Based on thesize and volume of tungsten you intend to grind, the replacement wheel cost can become a major
operating expense.

Wheel Core Exchange™
Arc-Zone.com now offers a Wheel Core Exchange program for your spent diamond grinding wheels!
Return your worn-out diamond grinding wheels to Arc-Zone.com, and we’ll give you a $25 check orstore credit. By turning in your used wheels, you’ll reduce the environmental impact of discarded
diamond grinding wheels. Better still, you’ll reduce the impact on your wallet!

Arc-Zone.com, Inc. • 1331 Specialty Dr • Vista, CA 92081 • Tel. 1.760.931.1500
Email: info@arc-zone.com

About ARC-ZONE.com
Jim Watson
Jim is CEO and founder of Arc-Zone.com. He is a master fabricator with years ofhands-on experiencein his own shop and also as a winning motorcycle racer, car builder, and chief mechanic
for a top motorsports team. He also has extensive experience in manufacturing, technicalsales, and product development. Before launching Arc-Zone.com, he held leadership positions
in some of the most respected companies in the welding industry.
Arc-Zone.com
Under Jim’s direction, Arc-Zone.com has led the industry in product innovation and online sales
and service, becoming the world’s leading supplier of high-quality, high-performance welding andmetal working tools and accessories.

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Arc-Zone.com, Inc. • 1331 Specialty Dr • Vista, CA 92081 • Tel. 1.760.931.1500
Email: info@arc-zone.com