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Straight answers to the questions people ask when choosing a TIG torch accessory kit.
A kit normally bundles the small consumable parts that sit at the front of a TIG torch: a few collets, matching collet bodies, ceramic cups in several sizes and a back cap. Some also include tungsten electrodes, but not all do.Contents vary a lot between kits, with different numbers of parts, cup sizes and tungsten diameters, so check the list or chart for the kit you are looking at. The usual idea is to give you a spare for each common tungsten size so you can swap sizes without hunting for parts.
Identify your torch series first. Most air- and water-cooled TIG torches belong to one of two common part families, often called the 9/20 (or 2 series) group and the 17/18/26 (or 3 series) group. Collet bodies in the first group are smaller than in the second.Parts from one family do not normally fit the other, although some adapter or stubby kits exist for particular combinations. Check the torch body, handbook or data plate, and the fit list for the kit, before ordering.
The collet grips the tungsten and has to match the tungsten diameter. The collet body is sized to suit it, and both must suit your torch series. If the collet is the wrong size the tungsten will not be held firmly, which causes a poor electrical connection, overheating and an unstable arc.That is why kits are normally built around a few tungsten diameters, such as small, medium and large. Choose the kit that covers the tungsten sizes you actually use.
For DC welding of steel and stainless, lanthanated and ceriated electrodes are widely used today, and zirconiated or pure tungsten has traditionally been used for AC on aluminium. Lanthanated tungsten is often recommended as a good all-round choice because it works on both AC and DC.Thoriated tungsten was once the standard for DC but has largely fallen out of favour because it is slightly radioactive. If a kit includes tungsten, check which type it is, and read the safety answer below before grinding any thoriated electrodes.
Choose the diameter by the welding current. Larger diameters carry higher current, while smaller ones make arc starting easier at very low current. A medium size is a versatile general-purpose choice for many jobs.A tungsten that is too small for the current can overheat, melt at the tip and contaminate the weld. One that is too large for the job can give a poor, wandering arc at low current. Each tungsten maker publishes a current range for each diameter, and AC usually allows a lower current than DC.
Cups are numbered by size, and a larger number means a wider cup. A larger cup gives wider gas coverage and suits more demanding jobs and longer tungsten extension, while a smaller cup gives better access to tight joints and uses less gas.Cup size is not set by tungsten diameter alone: it depends on the joint, the metal and the coverage you need. Many kits include a few sizes so you can match the cup to the job. A gas lens can improve coverage for the same cup size.