Weld Like a Pro

Grinding Tungsten
Electrodes

An ARC-ZONE.COM
Product Selection Guide

02-10-2022

GeneralMIG/GMAW

TIG/GTAW

Stick/SMAW

PlasmaGeneral/Multiprocess

The included grind angle (taper) and tip flat diameter (geometry) of a tungsten
electrode great affect the size and quality of the weld bead and penetration.

Introduction
With precision application like orbital tube and pipe welding or plasma arch welding, it is importantthat electrodes are precision ground consistently once a welding procedure is established. ArcZone recommends using a dedicated tungsten grinder, which allows you to pre-set the angle. Atungsten grinding machine is also safer than a bench grinder and some offer dust collection.
For highly mechanized welding operations purchasing pre-ground electrodes may be the bestsolution.
Always purchase your pre-ground tungsten electrodes from a trusted source like Arc-Zone.com
because manufacturing and grinding methods can greatly affect tungsten electrode performance.
Whatever your TIG/GTAW or plasma arc welding application, the electrode should be properly cutand tapered.

Selecting the Grinding Angle
Follow your equipment supplier’s suggested grind angle specifications first because they have
performed tests to determine the optimal electrode preparation for their equipment. If specifications
do not exist or you would like to change those settings to potentially improve and optimize yourparticular welding operation, use the following chart and table.

15˚

35˚45˚60˚90˚

120˚180˚

Sharper Electrode (Narrow Angle)

Blunter Electrode (Wider Angle)

Wider weld bead

Narrower weld bead

Easier arc startingMore difficult arc startingLess amperage

More amperage

Improved arch stability

Increased potential for arc wanderLess weld penetration

More weld penetration

Shorter electrode life

Longer electrode life

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

Grinding Electrodes
Use a dedicated tungsten grinder
to avoid contamination of theelectrode and to maximize welding
performance. Grind-ing wheels should
be made of diamond or borazon. Grind
longitudinally and con-centrically sothat the line on the ground surface
move in the same direction as thelength of the tungsten electrode andthe electrode has no flat spots.

TUNGSTEN

HSHIG

PEED ROTATIONDIAMONDWHEELTAROTATION
DURINGGRINDING

Cutting Electrodes
Tungsten alloys are dense and very brittle and can splinter or shatter, causing fractures in tungsten
electrodes. This can lead to arc instability or “break off” during welding, creating gross weld
defects.
When you need to cut your electrode to a specific length or remove contamination from thetip, be sure to cut the electrodes correctly. Incorrect
cutting methods damage the integrity of the tungsten
DIAMOND CUTTINGWHEEL
alloys, shorten arch time, and in-crease the potential
for tungsten contamination in the weld.
TUNGSTEN CUTTO LENGTHTo ensure quality cuts:•Use a diamond wheel with the electrode secured on
both sides of the cut.

•

Do not bend electrodes until they fracture.

•

Do not cut tungsten electrodes with wire cutters orpliers.

•

Do not notch the electrode on the grinding wheel
and then snap it off.

HOLDING FORK
ADJUSTABLE STOPST SCALE
ADJUSTABLE

Flat Tips
Pointed tips can burn off and drop into the weld puddle resultingin weld contamination and poor weld quality. After grinding theangle (taper), knock off the tip of the electrode as demonstrated
in the il-lustration. You may also grind a new flat tip prior to regrinding when reconditioning an old electrode.

DIAMOND
WHEEL

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

Safety Guide•

Never grind tungsten electrodes on belt sand-ers or the sides of standard grinding wheels.

•Do not breath grinding dust.

•Do not wear loose clothing, which may get caught in moving parts.

•Do not operate electrical equipment in or around standing water.

•Wear approved safety glasses.

•

Use an electrode grinding wand when grind-ing by hand to minimize burns and cuts. Splintered electrodes can penetrate the operator’s hands and eyes.

•

Use an exhaust system when grinding radio-active thoriated tungsten electrodes.

•Some discoloration may occur beyond the HAZ. Depending on the criticalness of the weld, that
may be acceptable.

About ARC-ZONE.com
Jim Watson
Jim is CEO and founder of Arc-Zone.com. He is a master fabricator with years of hands-on experiencein his own shop and also as a winning motorcycle racer, car builder, and chief mechanic for a
top motor-sports team. He also has extensive experience in manufacturing, technical sales, andproduct development. Before launching Arc-Zone.com, he held leadership positions in some of themost respected com-panies in the welding industry.
Arc-Zone.com
Under Jim’s direction, Arc-Zone.com has led the industry in product innovation and online salesand 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