TIG Front End Parts

An industry-standard manual gas tungsten arc welding (GTAW) torch package includes a torch
body and a cable set, either 12-1/2 or 25 feet long. Front-end parts generally aren't included. While
it may sound like the manufacturers are being cheap, it's really in your best interest because it lets
you customize your torch for the job at hand or to use front-end parts already in stock. Everything
from the handle forward is considered a front-end part. This includes gaskets, nozzles, collets, and
collet bodies that make the torch functional. Typically, the torch body in a package will have the
Teflon gasket installed (Figure 1). The gasket insulates the torch body from the gas nozzle. A torch
package also may come with a back cap but it may not be the one you need. The most common
styles of torches are the 17, 18, and 26 series that use the 10N series front-end parts (Figure 2) and
the 9 or 20 series torches that use the 13N series front-end parts (Figure 3). Most of these parts are
standardized meaning that a part from one manufacturer will fit another manufacturer's GTAW
torch. Be sure to ask before you buy, though, because some torch manufacturers make parts that fit
only their torches.

Figure 1
This 20 series GTAW torch with a medium back cap and a Teflon gasket.

To determine which front-end parts you need, first decide the type and thickness of the material
you will be welding. This will help you select which tungsten electrode type and diameter you will
need and, in turn, which size nozzle you will need. For example, if you plan to weld 1/8-inch
aluminum you will probably choose a 3/32-in.-dia. pure tungsten electrode (AWS Classification
EWP, green band), so you will need the 3/32-in. collet and collet body and a No. 6 or No. 7
nozzle. On the other hand, you might choose rare-earth tungsten (AWS Classification EWG, gray
or cream band) instead.

Figure 2 Figure 3
This 10N series collet and collet body are shown This 13N series gas lens collet body and collet are shown with an
with a Teflon gasket. alumina nozzle and Teflon gasket.

GTAW nozzles are measured at the side of the nozzle farthest from the torch body in 1/16-in.
increments at the inside diameter. For example, a No. 4 nozzle is 1/4 in. or 4/16 in. in diameter.
With the exception of a specialty torch, such as one for micro welding, the smallest nozzle is the
No. 4 and the largest is a No. 16, or 1-in. nozzle.
Nozzle Materials
Nozzles can be made of alumina, lava, Pyrex or quartz.

1. Alumina. The most common nozzles are made of alumina, a high-temperature,

nonconductive pink ceramic material that is injection-molded and mass-produced.
Alumina nozzles are durable and good for general use (Figure 4). These nozzles are
better for lower-amperage applications because the thermal shock of high-amperage
applications can cause them to crack or fall off. However, they're a common nozzle
choice because they're generally less expensive than the other types.
2. Lava. A tan/gray-colored, high-temperature, nonconductive clay material, lava is
mined and machined on a lathe for special sizes or odd-shaped nozzles and for long
(L), extra-long (XL), and extra-extra-long (XXL) nozzles (see Figure 5). Lava nozzles
work well in applications in which high reflective heat is present, but don't work as
well in confined areas with excessive heat, which can cause the nozzle to expand and
contract, resulting in breakage.
3. Pyrex and Quartz. Pyrex is a low-temperature, nonconductive glass material, while
quartz is a high-temperature, nonconductive glass material. These glass materials are
hand-blown to make nozzles for specialty torches for micro welding or standard
torches that allow for added visibility when welding in confined spaces. While the
Pyrex nozzles look good, the improved visibility doesn't add much benefit for
general-purpose welding. After all, you should be watching your weld puddle, not the
gas coming out of your torch. Also, Pyrex nozzles get dirty quickly.

Figure 4 Figure 5
This 13N series collet and collet body are shown with an This 10N series gas lens collet has a lava nozzle and
alumina nozzle and a Teflon gasket. a Teflon gasket.
Most GTAW torch manufacturers offer basic accessory kits that include a short back cap, a basic
set of alumina nozzles, an assortment of tungsten electrodes (usually 2 percent thoriated), and
collets and collet bodies in the most common sizes: 0.040 in. to 1/8 in. These accessory kits usually
are a good place to start, but when you're ready to optimize your torch for a variety of applications,
you'll need more front-end tools in your box and on your torch.
Improve Your GTAW Torch, Performance
With basic torch knowledge in hand, you should be armed and ready to find the best grouping of
front-end parts to help improve your GTAW performance. The following are three steps you can
take to enhance your GTAW experience:
 1. Change your collet body. One of the best improvements you can make to the
performance of your torch is to replace the standard collet body with a gas lens collet body.
A gas lens version is an enhanced collet body constructed of a series of concentric, layered
screens of varying mesh engineered to improve shield gas coverage. The screens generate a
laminar gas flow, optimizing the weld zone coverage and eliminating turbulence, which can
draw in contaminants from the surrounding air.

Using a gas lens collet body will help improve weld quality on all materials, but it's especially
beneficial with stainless steel and materials such as aluminum and titanium, which are
particularly sensitive to oxygen contamination. When welding those kinds of materials, you
also may need a flooding cup, trailing shield, or other device that can provide additional
shield gas coverage. Some of these devices attach directly to your torch, while others may
attach to a secondary gas source.

A gas lens also allows the tungsten electrode to be extended beyond the end of the gas cup
by as much as 1 in. This electrode extension helps improve visibility and can reduce tungsten
inclusions and weld defects.

2. Use the right tungsten. Using the right tungsten for your application will help you
optimize your torch's performance. While a manufacturer's welding calculator is a good
starting place, it's always a good idea to test first. Try an electrode out to see how easily the
arc starts, how long the tip lasts, how the tungsten reacts, and how it works, in general, for
you. Since the development of GTAW, many improvements have been made in electrode
production, such as additives that improve arc starting and tip life.
3. Prepare your electrode properly. Finally, be sure to prepare your tungsten electrode
properly, and always grind your electrode longitudinally, creating grind "lines" that run the
length of the electrode. This will reduce arc wander. Use a dedicated grinding wheel to
prevent electrode contamination. Grinding wheels should be made of diamond or borazon.
For added benefit, use a tungsten grinding machine that will allow you to select the grind
angle and repeat it.

Parts versus Consumables

The word consumable traditionally has referred to material that's consumed within the weld or in
the process of welding. Wire, rod, tungsten electrodes, and shielding gas are consumables. Front-
end parts often are considered consumables because they wear out or break and need to be
replaced. While they may not be the most inexpensive, well-manufactured GTAW torch
accessories are engineered to work together, eliminate tolerance stack-up problems, provide proper
torch insulation, and prevent gas leaks.

Make sure all the parts of your torch fit together properly to ensure that oxygen doesn't leak into
your weld zone and cause contamination. Note: if you're grinding thoriated tungsten, make sure to
control and collect the dust, have an adequate ventilation system at the grinding station, and follow
manufacturer's warnings, instructions, and material safety data sheets.