TIG welding amperage requirements

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I'm looking at getting a TIG welder in order to weld aluminum. The material will be mostly in structural tube and bar stock with thicknesses of 1/2" and under...mostly 1/4" and 3/16", though I do plan to weld tabs to thicker materials occasionally. The big question here is can I get away with one of the TIG welders producing amperages of 160 - 200 amps by using multiple passes on short welds,( say a 2" long x 1/4" thick tab), to thicker materials, (say 1" thick) plate ?
Reply:If its a routine thing, you may be money ahead to just buy a TIG unit with higher output from the get go.  Between the time you'll take preheating and the tanks of helium you'll be buying...
Reply:I have an arcmaster 185.  1/4" plate is about as big as it goes.  That is with wave balance around 25%, 25 Hz.  A water cooled torch would be good for you.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:You need a 300 amp watercooled machine and a gas mixer...Then you'll be all set.....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:That just depends on how big that 1'' plate is...you was doing pretty good until you mentioned that part. A couple sqare feet? If it was a regular thing then you're gonna need something bigger but for just a one time project a little pre-heat can go a long way (altho myself I just blast it with a ton of power when 200 amps ain't cuttin' it!!) I just got a 200 Dynasty and I will say it does amaze me so far..I looks like it'll do 90% of my mobile biz.Miller Dynasty 700Miller 350P with Aluma-pro push-pullMiller 280 Dynasty with expansion card Dynasty 200 DXMigMax 215 Enuff power and hand tools to create one of anything..... but mass produce nothing!!!
Reply:what ZAP said ,and even if you dont get a 300 amp'er 5min of tigingwith the machine maxed out and you'll beg for a water cooler torchChuckASME Pressure Vessel welder
Reply:No matter what get a cooler for the torch, your hand and the torch will appreciate it!! Aluminum takes A LOT of heat.
Reply:Thanks for the help ! I think that the 1" plate is definitely out, I'll just stick with bolted connections on that material. A water cooled torch would be neat, but I think that I'll just have to see how much of this I end up doing. I'll post some pic's when I get this going.
Reply:Originally Posted by SupeIf its a routine thing, you may be money ahead to just buy a TIG unit with higher output from the get go.  Between the time you'll take preheating and the tanks of helium you'll be buying...