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What are the rules regarding electrode size when matching with cup size.
I have found nothing written in a Miller book that explains this subject.
It's not about electrode size, rather than weld size. The bigger/wider the weld, the more coverage you need. Travel speed is a factor too. Fast travel can leave molten puddle uncovered, so an increase in trailing gas is desired. A bigger cup can help.
Nothing welded, Nothing gained
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The inside diameter of the gas cup should be at least threetimes the tungsten diameter to provide adequate shieldinggas coverage. For example, if the tungsten is 1/16" in diameter,the gas cup should be a minimum of 3/16" diameter.Figure 8.2 is an example of gas cup size and torch position.