TIG welding aluminum issues, please give advice.

[shenion]

The bushings are different from gas lens cups to traditional cups?

Yes, there is an extra ring:


WHen I switched to a gas lens I was missing the ring. I had two ceramics break before I realized the problem.

Without the ring, the ceramic bottoms out on the threads and when the collet holder heats up, it cracked the ceramic.

 

[Georgie]

shenion, i will be picking up ring tomorow..

anyone has an answer for this? What kind of machine do I have?? Square wave, sin wave, balanced wave or all three in one?

 

[shenion]

As an old transformer beast it will probably be sine wave.

 

[Georgie]

ok what does that mean?

 

[shenion]

Sine wave is just stepped-down voltage from the mains. Usually on these type of machines it is more of a flattened wave though. There is no smarts to dynamically control the waveform.

Square wave will alternate between + and - current near instantly so there is less off time in the arc. It helps the arc stability.

I don't see any balance control. It may be like mine and there is an internal optin by changing some jumpers. Usually it is set at 50%.

Square wave and balance control are nice but not necessary. It should work fine, I don't miss it on mine .

 

[wheresmejumper]

looks like balance control is top right of machine

 

[Georgie]

Ya balance.control is on the top right. It also has high frequency options, 3 of them :
-start
- continuous
-off

 

[Georgie]

Its also water cooled...

 

[Georgie]

Btw shenion, is the bushing in post#21 fit into the cup first?

 

[Georgie]

Comon guys, some of you must know what the pros and cons of my machine are..

 

[shenion]

Yes, the bushing can be inserted in the cup first but can be put on the torch first too.

As for pros and cons:

+ It is low-tech so will be reliable.
- Pulse mode is limited to low current DC range.
- Remote footpedal is probably unique to the machine (hard to find.)
+ it has lots of power
- It will draw considerable power.
+ has HF start

I have an even older beast with less features (no pulse) and still have no problems using it.

 

[Georgie]

Ok wll just finished welding a few notched pipe onto the hoops i made, not happy. Burned a few holes, so hard to close. When i tackle these joints, i tack first in 4 spots, then weld the 4 quadrants one at a time. Sometimes my filler gets rejected from the puddle, and thats when i mess up...

Ok its a square wave machine. That is confirmed. I just dont want my welds to fail !!

Ok thanks shenion. Since i didnt get that extra bushing yet, ive been using it without the gas lense.

Its weired, when i floor it the arc is continuous, but when i back off to avoid making a hole, the arc flickers...any reason why? Square wave?

Thanks!

 

[wheresmejumper]

when you size a tungsten,it is directly related to amps that your running.
it will have a certain optimum working range depending on ac or dc,and the characteristics of the machine.
if you you go above its range,it will erode the tungsten,but if you go below the arc will become less stable and flicker,dance about.
you might be falling under the range of your tungsten when backing off so as not to blow a hole

 

[wheresmejumper]

condition of tungsten tip will effect it too.
you said a couple of pages back youre using ceriated.ive never used them for ac

 

[Georgie]

Yes i am using ceriated. Ive also used lathanated and also thoriated. I havnt tried zirconated or pure yet. On the miller web site it says to use ceriated. But is there a different chart for a square wave machine?

 

[Georgie]

Is my machine an "inverter"?

 

[shenion]

No, it is not an inverter. If it was, it would be 1/3 the size

 

[Georgie]

Ok so maybe i need to use 1/16 tungsten instead? What do yall suggest on tungsten size/type + settings for these welds.

1.25 OD Aluminum pipe 60601 T6
.125 wall = 3mm wall thickness
R 5356 filler

Here are some examples of whats going on

This is the filler I am using


photo hosting

This is bassicaly how I start. Pipe laying on table, then weld 1/4 of the circumference starting from as low as I can go = the middle - up to about the top


upload pic

This is the same weld from above, just zoomed out


online photo storage

This is on the other end...


free screenshot tool

This is the same joint as the 3rd pic from the top, just the other 1/4 of the circumfrence. As you can see, I totlly ****ed this one up.



print screen windows

Notches done on Milling machine, all mating(for welding) surfaces are thoroughly cleaned with acetone and clean white 100% cotton fabric. Then I fit the pipe, brush joints with SS brush and proceed to welding..


photo uploading

 

[langy]

Ok so maybe i need to use 1/6 tungsten instead? What do yall suggest on tungsten size/type for these welds.

1.25 OD Aluminum pipe 60601 T6
.125 wall = 3mm wall thickness
R 5356 filler

Here are some examples of whats going on

I would use a 2.4mm white Zirconiated tungsten, ive never liked the ceirated grey much

 

[Georgie]

Isnt the white ceriated? Mine are grey but they are ceriated..