What might occur if the tungsten is not properly sized for the application?

If the tungsten is not properly sized for the welding application, it can lead to weld contamination and poor arc performance. The size of the tungsten electrode affects its ability to maintain a stable arc and achieve proper heat input. A tungsten electrode that is too small for the current being used may overheat, leading to melting or contamination of the weld metal. This can cause the formation of inclusions or defects within the weld, resulting in weakened joint integrity.

Conversely, an oversized tungsten can create excessive heat and a wider arc, complicating control over the welding puddle and negatively impacting weld quality. Proper sizing ensures that the tungsten can handle the required amperage without degradation and maintains a focused arc, which is critical for achieving clean and strong welds. Properly sized tungsten allows for optimal heat generation and minimizes the chance of contaminating the weld area, thus producing a higher quality and more reliable weld.