The welding current has a great influence on the wear of the tungsten electrode. The magnitude of the current directly determines the heat load, arc strength, and stability of the electrode during the welding process, thereby affecting the ablation, deformation, and lifespan of the electrode end.
Here are a few key aspects of the impact of current on tungsten electrode wear:
1.When the current is too large, the tungsten electrode is easy to aggravate the ablation
When the welding current exceeds the electrode bearing range, the temperature of the tungsten electrode rises rapidly, especially in reverse direct current (DCEP) or AC welding. High temperature will cause evaporation and melting of electrode materials, dull electrodes, shorten life, and even cause electrode tip dripping, polluting welds and producing “tungsten inclusions”.
2.When the current is insufficient, the arc is unstable and it is easy to arc difficult
Although the low current will not cause the electrode to burn out, it will cause arc discontinuity, difficulty in arc starting, or arc skipping. This instability causes the operator to frequently arc or reposition, indirectly accelerating mechanical wear on the electrodes.
3.Reasonable current can extend the service life of the tungsten electrode
Using tungsten electrodes within the recommended current range not only provides a stable and concentrated arc, but also significantly reduces electrode ablation and deformation. Maintaining the right current density (current to electrode area) is key to controlling electrode wear.
4.Different electrode materials have different tolerance to current
Thorium tungsten electrode has strong ablation resistance and is suitable for higher currents;
Cerium tungsten and lanthanum tungsten electrodes performed well at low and medium currents.
Pure tungsten electrodes are not suitable for high-current DC welding and are easy to ablation.
Therefore, choosing the right electrode type and matching the appropriate current is also an effective means to control wear.
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