Being new to this I'm probably looking at this a different or wrong way. It seems like the wire size should be the same as the tip. There is enough clearance between the 2 for easy slippage and it's called a (contact) tip so it can charge the wire. It just seems like a .010 larger tip then wire may cause a problem. I'm probably off base here but .035 aluminum wire and .035 copper tip seem fine for me so far. These pics are my rookie welds, the one on the right is cold and the left one is preheated to 225 degrees without changing the settings. The part is over 1/2" thick.
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