When using a balled tungsten electrode profile, what is the ideal size of the ball?

The ideal size of the ball on a balled tungsten electrode profile should be equal to the diameter of the electrode. This is because a properly sized ball allows for optimal heat concentration at the weld area, which is critical for effective arc stability and control during the GTAW (Gas Tungsten Arc Welding) process. When the ball is equal to the electrode's diameter, it ensures that the arc is effectively established, providing a consistent and focused heat source.

If the ball is smaller than the electrode diameter, it can result in poor arc stability and inadequate penetration. Conversely, if the ball is larger, it may lead to excessive heat input, causing potential burn-through or distortion in the base material. Having a ball that is half the diameter could compromise the ability to maintain a steady arc and produce a sound weld. Therefore, maintaining a ball size equal to the diameter of the electrode is essential for achieving the best welding performance.