CAS,
Here are a few things that have been written in the past. Normally, regular consumables can be used. They just need to be smaller. Don't forget, low amps means low light. You'll need to adjust your shade to match your amps.
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OK cas, here we are again. Yes the electrode will have to be around .040 dia. Power settings vary between .1A to 7A. The filler wire is .003" to around .025". Now, according to me, speaking of skill, this is probably the most difficult type of welding ever because it gets so miniature. There are very few Micro-TIG specialists and is a very closed community since their skill is learnt over many years of efforts.
Microtig (more recently micro-plasma and micro-laser) technology is used for 2 main purposes.
1. Manufacturing small miniature devices such as bellows, medical devices (pace makers, etc.)
2. Repair of very high tolerance tooling (specially plastic injection molds, metal injection molds, inserts, etc.) that may require a high degree of surface finish.
Micro-TIG process most of the times utilizes a special microscope with some exclusive lighting and some custom built parts on the microscope to be able to weld with it. You must understand that you will have severe visibility problems without the microscope. You will also require other special tools. Issues like correctness of tungsten shape, tungsten dressing, minor contamination, absolute cleanliness while welding and many many other factors play a significant role.
Regarding torches for micro-TIG, you can try Weldcraft or Linde. They have some very good small torches that can be easily manouvered while welding. However, if youre buying this you need to make sure your machine will go down to atleast 2 to 3Amps. There may not be a use for it otherwise.
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