Quote Originally Posted by ogorir View Post
"1/16 tungsten is WAY too small unless you are welding at something less than 20 amps, especially on aluminum. "
1/16" should be good up to 65A or so on alu or about 75 on SS. you'll probably want to put a land on the end of the tungsten for the higher end of any tungsten size's operable range.

you also might want to back the amps off, but if you're using a high high-to-low pulse current ratio, 98A sounds about right (just too hot for no pulse).



the diamond wheel in harbor freight's chainsaw grinder refill kit works well for sharpening tungsten with an angle grinder (not my idea, I'll try to find credit, it was someone else on this board). I just clamp it in the vise on the welding table.
For some reason, on our inverters, whether its the cycling frequency or what, the 1/16 tungstens suffer badly at 60-70 amps. Pulsing or NOT 98 amps are too hot because it heats the tungsten, to that temp and cooks it. Transformer machines MAY be able to go higher, but SO many of the "canned" and "boxed" recommendations floating out there are for transformer welders.