MIG welders advices: how to become a better welder and how to select the best welding equipment. For DCEN welding on steels, 1/16″ will work in the 20 to 100 amp rage as long as you prep it right. If you are using 20 amps, you will need a needle sharp point to get good crisp arc starts. At 100 amps, you might not want quite a needle sharp point or you might be putting a smidge of tungsten in the weld. You need a blunter taper. Some charts extend the range to 150 amps for 1/16, but I think that’s way too much. Why not just swap to a 3/32 at that amperage.? 3/32″ is good from about 65 – 200 amps. And 1/8″ 2% thoriated electrodes are good in the 85 – 300 amp range. ( Drop all these numbers by about 30% for A/C) Using helium mixed with the argon will also change the recommended currents because the arc is hotter with the same amps. These recommendations are from down and dirty experience and don’t come from a chart. Most charts I have seen tell you a 1/16 tungsten is good all the way to 150 amps…Please.
Argon is not the only shielding gas used for TIG welding: Shielding gasses for TIG welding Argon is not the only shielding gas used for TIG welding…just the most common and versatile. Argon will usually get the job done. But there are times when some helium mixed with argon makes a world of difference. Especially if you are using a small inverter TIG welder that is limited to around 200 amps. 100% Argon – is the most often used and coolest gas ..the best all around gas. 75% Argon/25% Helium – even 25% helium will make a big difference when welding aluminum that is thicker than .063″. Anything under .063″ thick and helium is unnecessary. 50/50 argon/helium—awesome for thick aluminum and magnesium 75% Helium/25% Argon – Awesome for thick aluminum castings… puddles really quick and welds cleaner than 100% argon. Also good for welding bronze and pure copper on DCEN.
All welding requires the application of heat, which melts the metal being welded. With the TIG process, the heat comes from an electric arc that streams between the electrode in a hand-held torch and the metal being welded. The arc and molten metal are shielded by an inert gas, which protects the electrode and base metal from oxidizing. Filler rod is usually added to the puddle of molten metal as the weld progresses. The essence of making a good weld is heat control, which is governed by how you modulate the arc as it streams from the torch. Let’s look at this in detail.
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Always know what gas your wire requires — whether it’s 100 percent CO2 or argon, or a mix of the two. \While CO2 is considerably cheaper than argon and good for penetrating welds on steel, it also tends to run cooler, making it usable for thinner materials. Use a 75 percent argon/25 percent CO2 gas mix for even greater penetration and a cleaner weld, since it generates less spatter than straight CO2. Here are some suggestions for shielding gases for common types of wire: Solid Carbon Steel Wire: Solid carbon steel wire must be used with CO2 shielding gas or a 75 percent CO2/25 percent argon mix, which is best used indoors with no wind for auto body, manufacturing and fabrication applications. Aluminum Wire: Argon shielding gas must be used with aluminum wire, which is ideal for stronger welds and easier feeding. Stainless Steel Wire: Stainless steel wire works well with a tri-mix of helium, argon and CO2.
