Help with smaller Tig Beads

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I am welding 3/8" aluminum bar stock to 3/4" for handrails.  I am new to welding thicker aluminum and my employer would like me to get smaller beads if possible.   I am welding at roughly 250 amps with with 1/8" ceriated tungsten, 1/8" filler rod (seems too thick), and a #6 cup.  My beads are coming out clean, but they are about 1/4" wide.  Does anyone have any suggestions on how to get smaller beads with material of this thickness?  Any help would be greatly appreciated.
Reply:Smaller wire diameter, high speed pulse if you have an inverter with the capability to do it.
Reply:Are you just welding the 3/8 to the 3/4 with the end of the 3/8 machined/ground flat?As suggested smaller wire is always good but if it's not available put a 45 degree chamfer all the way around on the 3/8 and fill as needed....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:Increase the AC frequency.
Reply:Post a picture. If you get in closer with more frequency (200+) and  2% lanthanated (blue) ground to a point. High enough amps where you have to weld fast as hell you can get the bead about as small as possible (emphasis on "as possible") . But that is something i only do for very specialized applications/situations (and anodized). Have other people welded to your bosses satisfaction? To me sub 1/4" welds on something like that (or anything) is a lot to ask. Some people don't know, and expect you to be able to get tiny welds like if you were welding steel. But if its an ugly bulbous weld i would understand wanting it better.www.performancealuminumfabrication.com
Reply:You could try a 50/50 blend of argon and helium. Sharpen your tungsten to a point.  Then work your balance up to 90%. That should increase the penetration without widening the bead as much. Only other way you are going to please your boss is to have him purchase a bottle of UTP Helium and you DC straight weld it with 4043. Good luck.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:Very valid tips from everyone! They all would work fine. Focus, concentration and experimenting pays off big time. Waste gas and money on your free time, it will go a long way. Here's a pic of a practice weld I was fine tuning my transformer old machine to get ready for a job that was all 1/16 edge weld with a 3/32 tung sharpened to a razor point.I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Originally Posted by weldermikeVery valid tips from everyone! They all would work fine. Focus, concentration and experimenting pays off big time. Waste gas and money on your free time, it will go a long way. Here's a pic of a practice weld I was fine tuning my transformer old machine to get ready for a job that was all 1/16 edge weld with a 3/32 tung sharpened to a razor point.
Reply:I had to cut up and cut back the ends on a Yamaha R1 exhaust and gut it, then reassemble. The exhaust was cut about a inch shorter on each end and there was no more room to use factory type spot welds anymore. So the edges were the only thing left to weld too. All in all it was a royal pain in the butt! Turns out the outer skin is titanium and the core was stainless! I got it done tho! Who can weld titanium to stainless? Me  And they said it couldn't be done! I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Originally Posted by travisc454Thats cheating haha. What kind of job required edge welding? I have never needed to weld an edge like that.
Reply:Originally Posted by weldermikeWho can weld titanium to stainless? Me  And they said it couldn't be done!
Reply:Originally Posted by SquirmyPugOnly you Mike! Did you use a vanadium filler to butter both sides before welding together or just deal with having a brittle weld? (something else?)  got me curious.
Reply:Originally Posted by weldermikeI used silicon bronze squirmy, and never lit up off the base metal. I touch the filler to the edge and with super low amperage feathering the pedal without breaking the flow of wire being melted i ran it around like laying out 14in of toothpaste so to speak.
Reply:Originally Posted by Showdog75So technically you brazed it, not welded.
Reply:That should increase the penetration without widening the bead as much.