Spray Transfer        Wire Size                  Volts                          Amps
                                                             .035"                           26-32                          175-240 HH
                                                             .045”                           28-33                          225-350
                                                             1/16”                           28-33                          240-400
                                                             3/32”                           30-35                          275-500

                        Short Circuit              Wire Size                  Volts                          Amperage
                                                            .035”                            19-21                          90-120
                                                            .045”                            20-22                          110-140      
                                                            .062                             22-24                          165-200

                                                 FCAW (Flux Cored Arc Welding)
 

                                           Wire Size                  Volts                          Amps
                                                          .045”                            20-26                          125-250       
                                                           1/16”                           23-29                          200-325
                                                           3/32”                           30-36                          450-700
                                                           1/8”                             36-41                          650-1000

                         Electrode Dia.          Amps
                                        3/32”                           50-90 
                                        1/8”                             70-125
                                        5/32”                           100-175
                                        3/16”                           150-225
                                        1/4"                             250-300
                                        3/8"                             450-600
                                        1/2"                             800-950
                                        5/8”                             800-1500
                                        3/4”                             1200-2100

 

                                          GTAW (Gas Tungsten Arc Welding), Aka TIG

Use direct current, straight polarity (DC-). Adjust the amperage according to the base metal thickness and tungsten diameters. Copper based materials may require significantly higher amps due to their strong thermal conductivity.