What should the tip of the tungsten electrode look like?

The appearance of the tungsten electrode tip is crucial for achieving optimal performance in Gas Tungsten Arc Welding (GTAW). A rounded and balled tip is the preferred shape, particularly for AC welding, as it promotes a stable arc and prevents contamination. This balling effect also allows for better heat distribution, which is essential when working with materials such as aluminum or magnesium that are commonly welded using GTAW.

When the tip is rounded, it provides consistent arc stability and helps to maintain the desired puddle size and control during the welding process. This shape also aids in transferring the electrical charge effectively, which is important for maintaining the desired amperage and achieving quality welds.

In contrast, other shapes such as flat and sharp, rough and jagged, or pointed and conical do not provide the same level of stability and control, potentially leading to erratic welding behavior and defects in the weld. Thus, a rounded and balled tip is optimal for ensuring a smooth, controlled welding operation.