Welding Tips and Tricks

I recently got a fantastic deal on 20 - 1/8" 2% Thoriated 7" electrodes. I don't even own a TIG welder yet but I understand they are too big for thin projects, like 1/8 and 3/32 sheet metal. Anyone help me here?

You can use any size electrode you want, all you need to do is change the grind angle for a tighter arc on the smaller stuff. Most guy's run 3/32 for everything. The 1/8 will handle more current but there's no limitiation on the other end of the scale. At least none that I've found. I ran 5/32 2% thor on a piece of 1/8" stuff yesterday because I was lazy and it didn't make any difference.

Thanks for the timely reply. Good news for me then.
Incidentally, I am really fascinated by the Everlast TIG inverter welders. Are you happy with yours. I will probably go with a 200 or 225 amp inverter type. Just an old hobbiest. Should have all the power I need. I already have a Hobart 120v - 140 amp MIG and a Lincoln Tombstone AC/DC.

For what its worth. Long story short had been using 3/32 on alot of 120 wall stuff went to a 1/16 and (at least to me) it seemed the haz was smaller and the weld apperance and heat color was better.

I'm happy with my 225 LX.

Very happy with my Everlast PowerTig 250ex

Tungstens sizes are according to current. It's common to use a tungsten that is max current rated close to the max current you expect to need to perform your weld. This method allows you to use the smallest tungsten possible so that you can maintain a tight and controlled arc. If you exceed the max current rating of the tungsten you risk spitting. Different tungsten compostions and diameters have different max current ratings and they can vary from manufacturer to manufacturer so make sure you read the packaging specs.

Knowing the max current rating of your tungesten and staying in that range will allow you to use just about any compositon you want. This is the reason that some folks swear by thoriated or lanthanated while others hate them and love pure or some other alloy.

My example is a bad one for newbies but this is it. I run 1/8 1.5% Lanthanated Sylvania Tungstens and weld 1/4" aluminum at 225amps with 80%ar/20%he. The max current rating on the package say's 200amps and indeed without the the mixed gas they will spit at 225 amps and I change to a 5/16.

Hope that helps.