What is the best tungsten for aluminum?

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The best tungsten for aluminum is not pure tungsten anymore.

Back in the day, the main two choices for tig welding were pure tungsten  for aluminum and 2% thoriated for steels.

Today there are several better options.

Especially when it comes to tig welding aluminum.

I like 2% lanthanated for TIG welding aluminum as well as an all purpose electrode for all metals.

When it comes to TIG welding aluminum, the choice of tungsten electrode matters for achieving the best weld quality.

The most recommended types of tungsten electrodes for aluminum welding are:

 1. Pure Tungsten (Green, WP)
- Usage: Pure tungsten electrodes are traditionally what was recommended for AC tig welding of aluminum back when transformer design tig welders were the norm. When AC balance settings became mainstream, welders started using other types of electrodes with a tapered tip to make the arc resemble a DC arc.

- Advantages: They provide a stable arc and have a balling effect at the tip, which is was beneficial for tig welding aluminum using a transformer style tig welder.
- Drawbacks: Pure tungsten has a lower current-carrying capacity and tends to wear out faster than other types.

 2. 2% Thoriated Tungsten (Red, WT20)
- Usage: While not typically recommended for AC welding, 2% thoriated tungsten can work just fine for AC welding of aluminum. Preparing the tip by either round using DCEP or a high cleaning AC balance setting is the key to making 2% thor work well on AC.
- Advantages: Thoriated tungsten has excellent arc starting and stability and is very durable. 
- Drawbacks: It is reported to be slightly radioactive, which raises health concerns, and it’s not ideal for AC welding. ( the final verdict on radioactivity seems to change year to year)

 3. 2% Lanthanated Tungsten (Blue, WL20)
- Usage: This is often considered the best all-around tungsten for both AC and DC welding of various materials, including aluminum.
- Advantages: Lanthanated tungsten electrodes provide excellent arc starting and stability, and they perform well at both low and high current settings. They are also durable and have a long lifespan. A tapered tip can be used for crisper arc starts at low amperage and for pinpointing the arc on fillet welds.
- Drawbacks: Lanthanated tungsten can be slightly more expensive than pure tungsten but offers better performance and versatility.

 4. Rare Earth Tungsten (Purple, E3)
- Usage: Purple tungsten electrodes are becoming increasingly popular for AC welding of aluminum due to their versatility.
- Advantages: These electrodes offer excellent arc stability, easy arc starting, and long electrode life. They work well with both AC and DC currents and have a low burn-off rate.
- Drawbacks: While more expensive than pure tungsten, the benefits in performance and lifespan often justify the cost.

 5. LaYZr tungsten electrodes from CK worldwide

Usage: good for medium amperage range welding for both aluminum and steels.

good low amp starts and good restarts.

to me LayZr tungsten welds the same as E3 purple tungsten.

 Conclusion

For TIG welding aluminum, 2% lanthanated (blue) and rare earth (purple) tungsten electrodes are generally the best choices. They offer superior arc stability, longer life, and versatility for both AC and DC welding. While pure tungsten is traditional and still widely used, especially for AC welding, the newer formulations of lanthanated and rare earth tungstens provide enhanced performance and are preferred by many welders.