Welding Tip Size Comparison Chart

Click here to download an Excel file with this info.

http://bikesmithdesign.com

Thanks to;
Attila Kokeny for the European manufacturers, Messer and CGE Rhona. They are not exactly the same sizes as the US tips they are aligned with, but close enough for comparison.
He also provided the Welding Thickness/Tip Size chart.

Aaron Novak supplied the #6, #7 and 1/2 size Meco Midget tip sizes.

Peter F. informs me that in Australia the big name in gas welding equip. is CIG. Their tip sizes, 6 thru 32, correspond to 0.6 to 3.2mm orifces.
Far too logical.
Welding Thickness Tip Size
Inches mm Drill
Size
Inches mm
1/64 0.38 76 0.020 0.51
1/32 0.78 72 0.025 0.64
1/16 1.59 68 0.031 0.79
3/32 2.38 62 0.038 0.96
1/8 3.18 56 0.047 1.19
3/16 4.76 54 0.055 1.40
6.35 51 0.067 1.70
5/16 7.94 48 0.076 1.93
3/8 9.53 44 0.086 2.18
12.70 40 0.098 2.49
5/8 15.88 35 0.110 2.79
19.05 30 0.128 3.25

Welding vs. Brazing
High gas velocities are important when welding. So you need to match the tip size to the material/joint.

Brazing bicycle frames is different. Some builders, myself included, will build an entire frame, from fillets to braze ons, with a single, large tip. Just by varying gas flow with the valves. (Maybe using a bit more pressure than my usual 4-5psi for larger fillets.)

I own every tip ever made for the Smith's AW1A , but I could get along just fine with just an AW205, which is big enough to weld 1/8" steel.

Other builders get good results using a tip as small as an AW201 for braze ons.

Wire
Drill
Decimal
Inch
Smiths
AW1A
Little
Torch
Harris Victor Meco
Midget
Messer GCE
Rhona
Metric
Eqiv.
97 0.0059
#2




0.15
85 0.011
#3




0.279
80 0.0135



#00

0.343
76 0.02 AW200 #4

0 00 00 0.508
75 0.022

0 #000


0.559
74 0.0225 AW20



0 0 0.572
73




0.5

0.572
71 0.026 AW201
1

1 1 0.66
70 0.028


#00 1

0.711
69 0.0292 AW202 #5


2 2 0.742
67 0.032 AW203


1.5

0.813
65 0.035

2 0 2

0.889
63 0.037 AW204 #6

2.5
2E 0.94
60 0.04


1


1.016
58 0.042

3
3

1.067
57 0.043 AW205





1.092
Wire
Drill
Decimal
Inch
Smiths
AW1A
Little
Torch
Harris Victor Meco
Midget
Messer GCE
Rhona
Metric
Eqiv.
56 0.0465 AW206 #7
2 4 3 3 1.181
55 0.052

4



1.321
54 0.055 AW207


4.5 3.5 3E 1.397
53 0.0595

5 3


1.511
52 0.0635 AW208


5 4 4 1.613
51 0.067

6



1.702
49 0.073 AW209

4 5.5
4E 1.854
48 0.076

7



1.93
47 0.076



6

1.93
45 0.082

8



2.083
44 0.086 AW210



5 5 2.184
43 0.089

9 5


2.261
42




7

2.261
40 0.098

10



2.489
36 0.106


6


2.692
35 0.11

13



2.794
Wire
Drill
Decimal
Inch
Smiths
AW1A
Little
Torch
Harris Victor Meco
Midget
Messer GCE
Rhona
Metric
Eqiv.