TIG Welding Rods

TIG Welding Rods (Filler Metal) for Australian Fabrication

TIG welding rods are the filler metal added to TIG welds to fill the joint, build up the weld bead, and (where dissimilar metals are joined) provide a metallurgically suitable bond. Different from the consumable-electrode processes (MIG, stick), TIG uses a non-consumable tungsten electrode and adds filler from a separate rod fed by hand into the weld pool. For Australian fabricators producing welds in steel, stainless, aluminium, and specialty alloys, the right TIG rod matched to the parent material is essential. AIMS Industrial supplies TIG welding rods from Bossweld and approved welding consumable brands.

The TIG rod grades we stock

• ER70S-2 mild steel — copper-coated mild steel for general TIG welding of mild and low-alloy steels
• ER70S-6 mild steel — higher-deoxidiser content for welding over rust and mill scale (where preparation isn't perfect)
• ER308L stainless steel — for welding 304 and 304L stainless
• ER309L stainless steel — for welding dissimilar metals (carbon to stainless) and 309 stainless parent material
• ER316L stainless steel — for welding 316 and 316L stainless; marine and chemical applications
• ER312 stainless — high-chromium for difficult-to-weld stainless and dissimilar applications
• ER4043 aluminium — silicon-content aluminium filler for general aluminium welding
• ER5356 aluminium — magnesium-content aluminium filler for higher-strength aluminium welding
• Silicon bronze and copper alloy rods — for brazing and dissimilar metal welding

Choosing the right rod

• Mild steel (general fabrication) — ER70S-2 for clean material; ER70S-6 where some surface contamination is unavoidable
• 304 stainless steel — ER308L for matching parent metal
• 316 stainless steel — ER316L for matching parent metal
• Stainless to carbon steel joints — ER309L bridges the dissimilar metals
• Aluminium 6061-T6 (general structural) — ER4043 for typical applications
• Aluminium 5052, 5083 (marine and high-strength) — ER5356 for matching strength and corrosion resistance

Match the filler rod to the parent material — wrong filler choice produces welds with poor mechanical properties or accelerated corrosion in service.

Rod diameter selection

TIG filler rod diameter is matched to the weld size and welding amperage:

• 1.6mm rod — fine welds, thin material, low amperage
• 2.4mm rod — the everyday workshop diameter for general TIG work
• 3.2mm rod — heavier welds, thicker material
• 4.0mm rod — heavy welds for production and structural work

Most workshops carry 2.4mm as the everyday rod with 1.6mm for thin material and 3.2mm for heavier work.

Where TIG welding earns its place

• Stainless steel fabrication — food-grade tanks, sanitary pipework, decorative stainless
• Aluminium welding — boat building, automotive, food-grade structures
• Thin material welding — sheet metal where MIG would burn through
• Aerospace and high-precision work — weld quality over speed
• Pipe root passes — TIG root with stick or MIG fill is common for pipe welding
• Custom and specialty fabrication — where weld appearance and quality matter

Storage

TIG filler rods don't have the moisture absorption issues of stick electrodes, but they should still be stored clean and dry. Surface contamination (oil, dirt, oxidation) on the rod transfers into the weld pool and produces weld defects. Keep rods in original packaging until use; clean any contaminated rod with acetone or solvent before welding. Aluminium rods in particular develop surface oxide that should be wiped off before use.

Brands stocked at AIMS

Bossweld covers the everyday TIG welding rod range — Australian-supplied and matched to the welding equipment commonly running in Australian workshops. Other approved welding consumable brands fill specific roles. For specialty alloys and grades, sourcing through our distribution channels covers most options.

Companion ranges at AIMS

TIG welding rods sit alongside our broader welding consumable range — see stainless steel welding rods (stick), TIG welding consumables, TIG welding accessories, and multiprocess welders for the related products.

Need help selecting TIG filler rod for specific parent material or weld application? contact our team — we'll match grade, diameter, and pack quantity to your work.