What is the Best TIG cup for Aluminum?

Is it a #6 gas lens?

…or a #5 cup with standard collet body?

Does it matter?

It definitely matters,

BUT it depends on what you’re welding.

Gas lens cups

Whenever I go with the gas lens setup, I use the smallest size gas lens cup that provides adequate shielding for the job.

The video shows a fillet weld on a tube that has 1/4″ wall thickness. I used a #6 gas lens cup on it.

A #8 cup would have also been just fine for this application, but would have required a bit more gas flow and since I was using a small 200 amp inverter welder along with a 17 air cooled torch, the #6 cup actually helped focus all the arc energy into the puddle instead of using up some for extra cleaning action outside of the bead.

(I know this might sound like total BS to some folks, but cup size and gas flow actually do affect heat input and when you are limited by the amperage of your welder, you learn workarounds)

I also use stubby gas lens setups quite a bit but having more mass in the collet body seems to help with an air cooled torch.

• I’ve recently started carrying a Large Diameter Gas Lens Kit on my store. check it out if you’re interested in upping your game on pipe welds
• The CK Stubby Gas Lens Kit is a very popular item on my store that is also a great gas lens setup.

Furick #8 pro clear cup

Another great cup I like to use for applications under 200 amps is the Furick #8 pro clear cup.

Not only is it a great all around cup for all metals, but its clear so there are times when I look right through it to weld in corners.

It also helps me see better.  I am in my 60s now and this cup really helps light the path and also really helps with me filming.

It works with 9 and 20 style torches simply by slipping an O-ring over the gas lens.

Learn more about the Furick #8 at the weldmonger store.

Stubby Gas Lens kit

I have both water cooled and air cooled TIG torches.

I love having water cooled torch, but I often use an air cooled torch anyway because I make welding videos for the average guy who typically goes with air cooled.

When I use a standard 17 style air cooled torch, I almost always use a stubby gas lens.

And when I TIG weld aluminum, I usually choose the #6 cup.

It just seems to be the best all around choice.

In the video, I used a #6 to weld a full penetration butt joint.

Standard #5 cup with collet body

The standard #5 cup is a go to cup for a lot of really good tig welders.

The photo above is a kit designed for use with #9 and #20 torches and its available now at weldmonger.com

I also recently added a simple #5 cup kit that works with #17,18, and 26 style torches..also available at weldmonger.com

One of the main benefits to using a #5 cup is argon savings.

a setting of only 12-14 cfh works in most situations.

For me, the #5 cups work great for 1/8″ and thinner aluminum.

Conclusion

The answer to the question…”what is the best tig cup for aluminum?”

is …

It really just depends on the type of work.

There are lots of options and there are ways to make one cup work for a lot of different situations…but a #5 is certainly a frequently mentioned option.