TIG Welding Consumables

TIG Welding Consumables for Australian Trade and Industrial Welding

TIG welding consumables are the wear parts of the TIG torch — the components that need regular replacement to maintain weld quality and torch performance. Tungsten electrodes wear and need re-grinding or replacement; ceramic cups crack from heat and impact; gas lenses clog with weld spatter; collets and back caps eventually wear. AIMS Industrial supplies TIG welding consumables from Bossweld and approved trade brands across the standard torch types and sizes.

The TIG consumable types we stock

• Tungsten electrodes — pure, thoriated, ceriated, lanthanated, and zirconiated tungsten in various diameters
• Ceramic cups (gas nozzles) — standard sizes #4 through #12 in alumina ceramic
• Gas lens cups — for use with gas lens collet bodies; improved gas coverage
• Standard collet bodies — basic gas distribution for everyday TIG work
• Gas lens collet bodies — fine-mesh gas distribution for better weld coverage
• Collets — for clamping the tungsten electrode in the torch
• Back caps — long, medium, and short back caps for different access requirements
• O-rings and seals — for the various torch components

Tungsten electrode types

• Pure tungsten (green tip) — for AC welding of aluminium; balls up nicely under AC arc
• 2% Thoriated (red tip) — the long-standard DC TIG electrode for steel; legacy material
• 2% Ceriated (orange tip) — modern replacement for thoriated; non-radioactive, similar performance
• 1.5% Lanthanated (gold tip) — versatile electrode that handles AC and DC well
• Zirconiated (white tip) — for AC aluminium welding; alternative to pure tungsten
• Multi-rare-earth (purple, rainbow) — premium electrodes blending multiple rare earth additions

The colour band on the electrode identifies the type — universal across manufacturers. For modern TIG work, ceriated and lanthanated electrodes have largely replaced thoriated due to the radioactive concerns with thorium dust generated during electrode grinding.

Electrode diameter selection

Electrode diameter is matched to the welding amperage:

• 1.0mm — up to ~80A; thin material work
• 1.6mm — up to ~150A; the everyday workshop diameter
• 2.4mm — up to ~250A; medium-heavy welding
• 3.2mm — up to ~350A; heavy welding
• 4.0mm — up to ~500A; production heavy welding

Ceramic cup sizes

Cups are sized by number — #4 (smallest, ~6mm bore) through #12 (largest, ~19mm bore). Larger cups provide better gas coverage and tolerate longer electrode extensions; smaller cups suit tight access. Match cup size to the work and the matching collet body and gas lens. For most workshop TIG welding, #6 through #8 cups are the everyday workhorse sizes.

Why gas lens cups matter

Gas lens cups, paired with gas lens collet bodies, distribute shielding gas through a fine mesh screen — producing significantly better gas coverage than standard collet bodies. The result is cleaner weld shielding, better appearance on stainless and aluminium, and tolerance for longer electrode extensions in tight access work. For sustained TIG welding, gas lens setup is the standard upgrade over basic torch consumables.

Consumable matching

TIG torch consumables are torch-specific. Bring us the torch make and model (or an existing consumable for cross-reference) and we'll match the right components. Common torch types (WP-9, WP-17, WP-18, WP-26) have well-documented consumable compatibility — most workshops settle on one torch type and stock matching consumables accordingly.

Tungsten grinding

Tungsten electrodes are sharpened to specific point geometry for DC welding (sharp point) or balled up for AC welding. Use a dedicated tungsten grinder or a fine grinding wheel with appropriate abrasive — diamond wheels are ideal as standard alumina abrasives can contaminate the tungsten. Grind in line with the electrode axis (longitudinal grinding) rather than across the axis (transverse grinding) — longitudinal produces a cleaner arc.

Brands stocked at AIMS

Bossweld is the core brand for TIG consumables — Australian-supplied and matched to the welding equipment commonly running in Australian workshops. For specific brand-OEM consumables (CK Worldwide, Weldcraft, etc.), sourcing through our distribution channels covers most options.

Companion ranges at AIMS

TIG welding consumables sit alongside our broader TIG range — see TIG torches, TIG welding accessories, TIG welding rods, and multiprocess welders for the related products.

Need help matching consumables to a specific torch or production volume? contact our team — we'll match by torch type, electrode size, and cup configuration.