tig welding .010 wall tube

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My dad and I are trying to do a job for a local business and are welding thinner wall stuff than we are a custom to. It is a.010 wall stainless tube that needs to be fuse welded to bigger tube that it's pressed into. The esab welder we are using doesn't like stabilize below 30amp, we are trying to use 1/16 tungsten. If anybody has any suggestion on how we could make this work please let me know. If a new machine is needed please recommend those, we feel this job could continue for a while so we wouldn't care to buy a welder obviously a good bit not great welder can't afford to dump a ton of money in it.  Thanks
Reply:Have a pulse setting? If its autogenous, pulse helps a lot with thin material. Set the peak to like 40 or so and the base as low as you can get it. Just blast a little bit to get a bead going then when the amps go down the puddle freezes up. Or manually pulse with a pedal.
Reply:You should be able to get a stable arc with 1/16" tungsten, but if you can't you can get smaller. You may need to turn the high frequency down lower so it will quit trying to start an arc.Airco Ac/Dc 300 HeliwelderMillerMatic 200 (stolen)Miller Maxstar 150STLMiller AEAD200LE (welding and generating power) Hobart MIG
Reply:Those jobs I use my Dynasty200DX. Yes a bit pricy, but the pulse goes up to 500pps. The arc is really cold then. The default peak setting and background setting work fine for me and have not had to reset it. Then there is the arc start. You press gas/dig and "Amps" button under the dial and goes right to the tungsten diameter arc start setting. You might want to go with .040" diameter and set for that. I think there is a softer start at .020" but you may not be able to start then. You should be able to start an arc and not melt the metal. Guys here have done razor blades. There are other offerings. I also have Dynasty350s and a 700. Those go up to 5000pps pulse. You have to wear earplug with that. I have never found an application for 5000pps. Maybe someday.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:Get some thick braided copper wire and wrap the crap out of it.Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:Originally Posted by GambleGet some thick braided copper wire and wrap the crap out of it.
Reply:Originally Posted by Showdog75Care to elaborate?
Reply:Originally Posted by dart daddyThe esab welder we are using doesn't like stabilize below 30amp, we are trying to use 1/16 tungsten.
Reply:We have renteda dynasty 200dx to help us with this job.  We are still having a little trouble getting all the way around the 1/8th with out starring to melt the end of the part. We only had the pulses set at 40 pps, 25% background. We haven't messed with a pulse setting that much so all suggestion welcome.  Please elevate on how to change the tungsten diameter in the settings.
Reply:Originally Posted by dart daddyWe have renteda dynasty 200dx to help us with this job.  We are still having a little trouble getting all the way around the 1/8th with out starring to melt the end of the part. We only had the pulses set at 40 pps, 25% background. We haven't messed with a pulse setting that much so all suggestion welcome.  Please elevate on how to change the tungsten diameter in the settings.
Reply:Is the joint configuration fillet, lap, or butt?Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:It reads like a lap or fillet weld to me....I'd also suggest a .040" tung and crank up the ops. A lot of good tips and info above.Last edited by Rick_H; 01-16-2015 at 10:41 AM.AWS 17.1, D1.1 and ASME IX (GTAW)Miller Syncrowave 350LX, Maxstar 150sth, Maxstar 200DX and  Millermatic 252 w/ Spoolmatic 30aMiller buzz box with Lincolin TombstoneThermal Dynamics Cutmaster 38
Reply:Originally Posted by MikeGyvereven 1/16 is technically way too big, it's only recommended for use down to 70amps. You should be using .040". You might be able to get away with it if you grind the tungsten to a verrrrry long tapered point.
Reply:How about brazing it instead of welding?
Reply:How thick is the bigger tube that the 0.010" tube is being pressed into?Mike ZanconatoZanconato Custom Cycles @mzank on Instagram