Hi,

I need to weld a new tab onto a small steel part where the original one broke off. The piece is about 1.5 in square and is about .025" thick. There are 4 tabs that stick up vertically off each side of the square. Tabs are about 3/16" wide by 3/8" tall, also about .025" thick. The piece was originally stamped out, and then the tabs were bent up vertically. I cut a new tab, and the plan is to weld it on.

So I'm going to TIG it. I tried some experiments on similar thickness stuff, and melted the crap out of it. Any tips on how to approach this? I'm really doing it for the challenge and the learning. How much current should I be using? My machine goes down to 5 amps. Tungsten size? How about .040", Ceriated?

Thanks.