The welding current range for different diameters of tungsten electrodes varies. The thicker the electrode, the greater the current it can carry; If the electrode is too thin but the current is too high, it can cause the electrode to overheat, burn out, or arc instability. The following is the reference range of common tungsten electrode diameters and corresponding welding currents:
Tungsten electrode diameter and recommended current range (DC positive DCEN)
| Tungsten electrode diameter | Recommended Current Range (DC) | Recommended Current Range (AC) | Instructions for application |
| 1.0 mm | 5–70 A | 10–60 A | Thin plates, precision welding |
| 1.6 mm | 20–150 A | 20–130 A | Universal size, widely used |
| 2.4 mm | 80–200 A | 60–180 A | Welding medium-thickness metals |
| 3.2 mm | 150–250 A | 100–240 A | Thick plate, high current welding |
| 4.0 mm | 200–320 A | 160–300 A | Heavy-duty welding, large-piece welding |
Illustrate:
The above table is a general recommendation, and it should be fine-tuned according to the electrode material (such as thorium tungsten, cerium tungsten, lanthanum tungsten, etc.), the type of welding material (such as stainless steel, aluminum, titanium, etc.) and the thickness of the workpiece during actual use.
For AC welding, the electrode is subjected to a higher heat load due to the arc switching between the positive and negative electrodes, and a slightly lower current is generally used, and electrodes with strong spheroidization resistance (such as zirconium tungsten) are recommended.
When welding thin plates, it is recommended to take a low value, and when welding thick plates or need to penetrate deeply, the current can be gradually increased to near the recommended upper limit.
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