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Practical welding guide

A practical guide to TIG and MIG/MAG welding: choose a tungsten electrode by colour and base metal, estimate shielding gas and welding wire consumption, and set a suitable argon or Ar/CO₂ flow rate in l/min.

Which tungsten electrode should you choose for TIG welding?

Tungsten electrode colour codes — choosing electrodes for steel, stainless steel and aluminium

Choose your tungsten electrode according to its colour code, the base metal and the TIG current type — AC or DC. This table compares green, grey, purple, gold and blue electrodes for TIG welding steel, stainless steel, aluminium and other metals.

Code and colourCompositionCurrentSuitable metalsPractical use
WP — greenPure tungstenACAluminium, magnesiumMainly for older transformer TIG machines; doped tungsten is generally preferred for modern inverters.
WC20 — grey2% cerium oxideAC / DCSteel, stainless steel, titanium, aluminiumEspecially suitable for low to medium currents, thin materials and frequent arc starts.
E3 — purpleMixed rare-earth oxidesAC / DCSteel, stainless steel, aluminium, copper, titaniumA versatile electrode with reliable arc starts, long service life and good performance across a wide current range.
WL15 — gold1.5% lanthanum oxideAC / DCSteel, stainless steel, aluminium, titaniumA versatile choice with good arc starting and stability across a wide current range.
WL20 — blue2% lanthanum oxideAC / DCSteel, stainless steel, aluminium, nickel, titaniumA versatile electrode for modern inverter machines, offering a precise arc and good current-carrying capacity.

Polarity: steel, stainless steel, copper, nickel and titanium are generally welded using DCEN (DC−); aluminium and magnesium use AC. Always follow the TIG machine and electrode manufacturer’s instructions.

How much wire can you weld with the gas in your cylinder?

Shielding gas duration and estimated MIG/MAG wire quantity

Enter the cylinder capacity and current pressure, the gas flow rate and your welding wire parameters. The calculation estimates how long the cylinder will supply gas at this flow rate and how many kilograms of wire could theoretically be fed during that time.

Cylinder and wire parameters

Estimated wire quantity
—
Gas in the cylinder—
Usable gas for the calculation—
Active gas flow duration—
Wire consumption—

Indicative calculation. The result is not a production guarantee. Actual consumption depends on regulator accuracy, cylinder temperature, leaks, pre-flow and post-flow, gas delivery during pauses, the proportion of arc-on time, wire slippage and process settings. The amount of wire actually welded will usually be lower than the theoretical result.

What shielding gas flow rate should you set for TIG and MIG/MAG welding?

Suggested argon and Ar/CO₂ flow rates in l/min by process and material

The table gives practical starting ranges for indoor work without significant draughts. Adjust the flow for nozzle size, torch distance, current, joint geometry and ambient conditions.

Welding processMaterialTypical shielding gasStarting flow rateNote
TIGCarbon steelArgon6–10 l/minA gas lens often allows a lower flow rate.
TIGStainless steel / titaniumArgon7–12 l/minClean gas shielding is essential; pipes may require root purging.
TIG ACAluminium / magnesiumArgon8–14 l/minA larger nozzle and higher current may require more gas flow.
TIGCopper and its alloysArgon or Ar/He10–16 l/minFor helium mixtures, correct the reading according to the flowmeter specifications.
MIG/MAGCarbon / low-alloy steelAr/CO₂ or CO₂10–14 l/minA practical starting estimate: wire diameter in mm × 10.
MIG/MAGStainless steelAr/CO₂12–16 l/minUse the mixture recommended by the wire and gas manufacturers.
MIGAluminiumArgon14–19 l/minA greater torch distance or draughts increase the required flow rate.
MIG brazingCuSi3 / galvanised steelArgon or a suitable mixture10–14 l/minSet the parameters according to the wire’s technical data sheet.

Important: excessive gas flow does not improve protection — it can cause turbulence and draw ambient air into the weld zone. In draughty conditions, use a screen first, then increase the flow moderately if needed.

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