Help on welding aluminium

[big star]

Hi. I'm new here so hi to all.
I've been TIG welding for a few years now. It's something I fell into. I usually do the same kind of stuff - I mean same kind of work, generally always 16G alu and 20G stainless corner welds. However, I have been given a task that involves 3mm alu butt welds and I'm thrown. Can anyone advise me on what size tungstens I should be using on this, should I use a bigger shroud? What size filler rod? What kind of gap? Any general tips, advice? I've practiced and the tungsten tip goes ball like but also turns black, is that normal? It tends to remain clean with the 16G. The shroud goes red hot too. I don't want to tell the boss I'm struggling.
Thanks for any advice.

 

[weldequip]

Which size tungstens are you using at the moment, 1.6mm? & what's your TIG torch, WP17, 26 ??
weldequip

 

[big star]

Hi Weldequip. Yes I'm using 1.6. I have a pack of 2.5's unused, and some bigger shrouds. Should I be using those? The torch I belive is WP17, although I wouldn't bet my life on it. Not really a welder you see. I learnt to do it to a passable level just through necessity.

 

[weldequip]

Stick it on the 2.4mm tungstens, Zirconiated (white tip) or Ceriated (grey tip), round the tip, not point & you should be OK. You can also change the ceramic gas nozzle to a 'gas-lens' or 'large diameter gas lens' to give you better gas coverage over the standard set up.
weldequip

 

[big star]

Thanks. I only have white and red tips. When I say shroud (the ceramic thing) is that a gas lens? It's pinkish. I have them with a 10mm-ish dia opening and others with a 12mm-ish opening. And filler rod?

I really appreciate your help.

 

[weldequip]

Use the 2.4mm white tip tungsten & the largest ceramic ('pink thing'!) you have with 2.4mm filler rods & you should be fine. Make sure the filler rods are correct for the the aluminium you are welding; 5356 for general purpose, sheet aluminium & 4043 for cast/wrought aluminium. If you are still having problems with the tungsten going black, up the ceramic nozzle size/turn your amps down a little.
weldequip

 

[big star]

Ok. Excellent. I'm feeling more confident already.
Thanks again.

 

[lexi]

I thought zirconiated was for steel?

Alex

 

[weldequip]

Nooo Alex, Zirconiated (white tip) for AC, Aluminium & Thoriated (red tip) for DC, Steel, S/Steel etc.
There are also other variants such as Ceriated (grey tip) which will do both AC & DC.
weldequip

 

[dj graham]

aluminium

hi im new so can you tel mehow to weld alum i have a wse200p super same as a butler. can you tel me the settings pre flow time peak current basic curr pulse freq clean width gas flow. it cos £800

 

[muskt]

Alex, here is a link to an article that may help with the Tungsten questions.

http://www.thefabricator.com/ArcWelding/ArcWelding_Article.cfm?ID=1276

Jerry in Alaska (The large northern colony.)

 

[Seano]

Nooo Alex, Zirconiated (white tip) for AC, Aluminium & Thoriated (red tip) for DC, Steel, S/Steel etc.
There are also other variants such as Ceriated (grey tip) which will do both AC & DC.
weldequip

Just out of interest WQ, and not wishing to hijack the thread I only use Gold and Black tipped lanthanated now and find them excellent, if a little expensive...

Sean.

 

[cemkarakurt]

hi im new so can you tel mehow to weld alum i have a wse200p super same as a butler. can you tel me the settings pre flow time peak current basic curr pulse freq clean width gas flow. it cos £800

i am not a profesinaol but as i see in the dvd tig welding tip they saing pri flow 3-4 sec. post flow is evry 10 amp 1sec. so if yousing 100amp 10sec. and you need to hold same place antil post flow stops.
hope this will help you.