The PowerWeld ZIR040 .040″ x 7″ 1% zirconiated brown tungsten electrode is designed for AC TIG welding on aluminum and magnesium where weld cleanliness is critical. This small-diameter .040″ tungsten is ideal for low-amperage work on thin sheet, light-gauge tube, and detailed aluminum components. Classified as EWZr-1, it uses a zirconium oxide blend that helps the electrode resist tungsten contamination of the weld pool while maintaining a stable balled tip under AC. The result is a consistent arc that supports smooth bead appearance and controlled penetration on light non-ferrous material.
Because it is intended for AC operation, this zirconiated tungsten electrode performs especially well on transformer and inverter AC TIG machines set up for aluminum TIG welding. The 7″ (175 mm) length fits standard TIG torches and most tungsten grinders, while the brown color coding at the tip clearly marks it as zirconium-bearing tungsten in a crowded storage rack. Welders who focus on thin aluminum panels, small castings, or magnesium components will find the ZIR040 size well-suited to the lower amperage ranges used to avoid burn-through and distortion. Sold by the each, this EWZr-1 TIG tungsten can be purchased individually or ordered in groups of (10) electrodes to match a full PowerWeld pack.
PowerWeld .040″ x 7″ 1% Zirconiated Brown Tungsten Electrode At a Glance
- EWZr-1 Zirconiated Tungsten: Designed to reduce tungsten contamination in the weld pool on AC TIG.
- .040″ Diameter: Best for low-amp AC TIG welding on thin aluminum and magnesium.
- 7″ (175 mm) Length: Standard length that fits most TIG torches and tungsten grinders.
- Brown Tip Color Coding: Identifies the electrode as zirconiated tungsten in mixed storage.
- AC Operation: Performs with alternating current, keeping a stable balled end while welding.
- Clean Weld Support: Preferred when weld cleanliness and minimal tungsten inclusion are important.
- Non-Ferrous Focus: Optimized for aluminum and magnesium TIG welding applications.
- Sales Unit: Each; order (10) electrodes for a complete PowerWeld pack.
Markets
- Aluminum Fabrication Shops Used for AC TIG welding on thin aluminum sheet, tube, and light structural parts.
- Marine and Trailer Manufacturing Suitable for aluminum boat components, docks, ramps, and trailer frames.
- Aerospace and Aviation Maintenance Helpful for aluminum and magnesium repair work where weld quality is critical.
- Automotive and Motorsport Fabrication Applied to aluminum panels, intercoolers, intake parts, and brackets.
- Manufacturing and Process Equipment Used on aluminum tanks, guards, frames, and machine covers.
- Municipal and Facility Maintenance Practical for AC TIG repairs on aluminum railings, signage, and fixtures.
- Trade Schools and TIG Training Programs Good choice for teaching proper AC aluminum TIG techniques with zirconiated tungsten.
Aluminum fabricators, automotive builders, and maintenance crews turn to the PowerWeld ZIR040 when they need tight control over AC TIG welding on thin non-ferrous material. The small .040″ size lets welders run lower amperage, which helps manage heat input on sheet and thin-wall tubing, reducing the risk of burn-through and excessive distortion. In shop and field settings, crews benefit from a zirconiated tungsten electrode that is designed to keep a clean, balled tip on AC while limiting the chance of tungsten inclusions in the weld metal.
Training programs and production lines see similar advantages. Instructors can demonstrate proper AC TIG setup on aluminum using an electrode that behaves predictably at low amperage, while production welders appreciate being able to make consistent beads with fewer issues related to tungsten contamination. For any operation where thin aluminum or magnesium parts are common, the PowerWeld ZIR040 provides a focused solution for AC TIG work that demands clean welds and steady arc performance.
PowerWeld ZIR040-EA .040″ x 7″ 1% Zirconiated Brown Tungsten Electrode (EWZr-1) Features
- Minimized Tungsten Contamination: Zirconium blend helps reduce tungsten inclusions in critical aluminum welds.
- Stable Balled Tip on AC: Retains a controlled balled end during AC TIG welding for smooth arc behavior.
- Thin-Material Control: .040″ size supports low-amperage welding on light-gauge aluminum and magnesium.
- Consistent Arc Performance: Provides steady AC arc characteristics for better puddle control and bead appearance.
- Non-Ferrous Focus: Optimized specifically for aluminum and magnesium rather than general steel work.
- Brown Identification Band: Standard color coding indicates zirconiated tungsten at a glance.
PowerWeld ZIR040-EA .040″ x 7″ 1% Zirconiated Brown Tungsten Electrode (EWZr-1) Includes
- (1) .040″ x 7″ 1% Zirconiated Brown TIG Welding Tungsten Electrode (EWZr-1)
- Order (10) pieces for a full PowerWeld pack.
PowerWeld ZIR040-EA .040″ x 7″ 1% Zirconiated Brown Tungsten Electrode (EWZr-1) Specifications
- Brand: PowerWeld
- Model / MFG Part #: ZIR040
- Product Type: TIG Welding Tungsten Electrode
- Electrode Classification: EWZr-1 (1% Zirconiated)
- Diameter: .040″ (1.0 mm)
- Length: 7″ (175 mm)
- Composition: Approx. 99.0% Tungsten, 0.15%–0.5% Zirconium, 0.5% Other
- Current Type: AC
- Process: TIG welding
- Recommended Materials: Aluminum, magnesium
- Sales Unit: Each
- Recommended Order Quantity: (10) Electrodes for full pack
- UPC: 775709997172
Why Customers Choose the PowerWeld .040″ x 7″ 1% Zirconiated Brown Tungsten Electrode
Welders choose the PowerWeld ZIR040 when they need a .040″ zirconiated tungsten electrode dedicated to AC aluminum TIG welding. The EWZr-1 chemistry is preferred for applications where tungsten contamination of the weld must be kept to a minimum, such as thin aluminum panels, small castings, and light structural components. On AC TIG, this electrode maintains a stable balled tip, which helps keep the arc smooth and predictable while spreading heat in a controlled way across the joint.
In shops and training environments, the small diameter lets technicians run lower amperage settings and achieve fine control over the weld puddle on thin aluminum or magnesium. That can mean less rework, fewer warped parts, and a more consistent weld profile from piece to piece. For builders and repair crews looking for a dedicated AC TIG tungsten for light non-ferrous work, the PowerWeld ZIR040 zirconiated tungsten electrode offers clean, reliable performance in a size that matches precision jobs.
Please Note: Image may differ from the product listing. The image represents the correct electrode type, but the size shown may not match this .040″ x 7″ model. Always verify the description and specifications above before ordering to ensure you select the correct tungsten size.
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