HI, looking at a 200amp arc welding which takes 4mm rods I have seen others that will take 5mm. Is there a big difference in the thickness I can weld or is it the case I just do multi passes?
You won't need more than 4mm rods and multi-pass. I'd be inclined to buy a decent well know inverter (150-ish amp) which will run a 4mm rod, but I normally use 3.2mm multi-pass.
its not the amps that allow you to welder thicker material it just allows you to burn a bigger rod.... thus cutting the time down. Inverters are certainly the smoothest and i would always recommend one. it depends what your going to be doing with it.if your using it all the time you want at least 200 amps... but if its hobby stuff your doing you will pick up a cheap one thats about 140-160A