Tungsten Geometry "the universal grinding procedure?"

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Iv'e seen aluminum tig welding and tungsten grinding as a topic of debate since i started my career. I use a belt sander used strictly for tungsten to grind peices flat (squre end, not tapered) after making a rough break with a hammer. Is there anything wrong with this? Is this the a correct method? I understand in thery you are supposed to cut contaminated edges with a diamond wheel but i don't have acces to this.
Reply:It is normal to break a tungsten. It is usually a clean break just by the nature of the material.I have always had good results with a sanding disk. I use zirconium blue sanding disks, 100 grit. You can use a table disk sander or a 4 inch hand sander/grinder.  Do not sand transverse to the tungsten. Sand parallel to the tungstens length. You want a point that looks like a pencil point 70º. The smoother the sanding, the longer the tungsten will perform.A 4 inch grinding wheel is WAY TOO ROUGH to do this job. The tungsten would not last long and the arc may initiate from the side of the tungsten instead of the point.Last edited by Donald Branscom; 03-02-2008 at 07:47 PM.
Reply:i thought you were supposed to have a completly square edge on the end of the tungsten for ac aluminum not a 70 degree or at leat thats what i was told in tech school-thank you for the reply
Reply:square would be best but the tungsten will ball up either way.
Reply:i grind mine to a point and some times maybe knock off the point  but looks like the pencil thing also
Reply:I have a pedestal mounted grinder with a fairly course wheel on it..No guard..Stand behind it and use the top of the wheel for grinding and the sparks go away from you..Cordless drill makes a great tungestion turner..As the grooves build up here and there on the wheel save them..They make good guides for diffrent "applications".....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:For AC tigging aluminum I don't grind a point as it will ball up anyway.  I break it off, and clean the end up on a fine grinding wheel then start welding.  It won't take long on AC to ball the end.I'm a Lover, Fighter, Wild horse Rider, and a pretty good welding man......
Reply:I don't bother sharpening the tungsten for aluminum.   I just get it fairly flat on the end before balling it with the AC current, then start welding.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:cordless drill??? that seems like something i will have to try, as my tig gloves usually have fine slits in the thumbs from hand turning. I never realize this until its too late eithermucho ouch