Determining Tungsten Size Per Amperage???

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I was using my TA 185 Arcmaster the other day. The project was a welding/work table made out of aluminum for use outside. The top is 1/4" aluminum welded to the frame which is 1"x 1"x 1/16" square tube. Right or wrong...........the way I welded this was to concentrate the heat on the 1/4" and then manipulating the puddle over to the square tube. This worked.Heres where it gets unsure. I was using 3/32 1.5% Lanthanated tungsten running at 185 amps. I did work with the AC balance and no matter what the setting was the point on the tungsten burned off in short order. Would I be better off with 1/8" tungsten???This leads to the main question...........at what amp ranges are you guys using 1/16", 3/32" and 1/8" tungsten???
Reply:For AC, yup you'd be better off with a 1/8" tungsten to better handle the heat of the reverse wave of the AC signal. 1st on WeldingWeb to have a scrolling sig! HTP Invertig 400HTP Invertig 221HTP ProPulse 300HTP ProPulse 200 x2HTP ProPulse 220MTSHTP Inverarc 200TLP HTP Microcut 875SC
Reply:My machine goes up to 450+ Amps...From beer cans to giant rollers all I use is 3/32" Red....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:It depends if you have frequency control. On my machine, it is fixed. So anything above 140-150 amps A/C gets hairy at 60% DCEN, and starts to ball up the tungsten in short order. The cleaner you can get your AL, the higher the DCEN % you can run, and reduce tungsten balling. This is all with 2% lantanated tungstens.
Reply:Having the tungsten ball back to the original width or larger isn't really a problem, you'll just use up more tungsten. I'd run 1/8" at that heat. I've tried the red on AC, it works OK but the point forms more of a monkey's paw than a ball. At work we don't have time to buff and clean everything, I use high balance and big tungsten instead. Everything gets ground smooth and painted though, the big etch area may not wok for everyone.Gold/blue tungstens for AC : 1/16": 10-70a,  3/32": 50-160a, 1-8" 160-up.Last edited by Brazin; 06-22-2014 at 10:02 AM.SqWave 200Millermatic 190Airco 200 ACHypertherm PM45Boice-Crane Band SawVictor O/A