Ok im pretty new to welding alum and this is honestly my second project with it. I could use some pointers and some constructive critisizm. Welder is a Miller 200 syncro. Amps 115-130ish, and yes i did cheat and pulse was on 10 pps.

 

looks dame good to me

 

What...
Filler/size
Tungsten/size

Over all they look pretty decent for just starting out. Looks like you have somewhat of a feel for adding the filler. The pulser helps immensely in keeping on rythem as a beginner. Don't get dependant on it though.


Some of your starts and stops look a little suspect. There is one corner in particular where you can see a crater at the very end of the weld. Try backing the amps off as you near the end of the weld, add one last dab of filler and drop your amps as you pull the arc to the side. Try to break it as softly as possible and preferably a little off the the side of the bead so if there is a slighty crater it's in an area where it's not going to leak/break(hopefully) good news is that you can always fill craters in after teh fact.

Some of your starts look a little contaminated and cold, possibly from addiny the filler just a little bit before the puddle is ready to accept it.


Your circular fillet welds could use some work but to be honest this is one of the harder joints to learn for AL. It's just difficult to move as fast as you need to just starting out. Make sure you are hot enough that when you start your puddle its connecting the two pieces. I'm not really sure how to explain this well. Maybe someone else can take a stab at it later. Basically, you need to focus your arc at the very root of the fillet so that you aren't creating two independent puddles on the fitting and the flat stock. Try to weld that cold will result in super slow travel speeds and mad heatsoak. I know it's scary to burn those fittings up though It helps to adjust your ac balance to max penetration when doing fillets. You will get a narrower puddle thats easier to concentrate in the root of the joint. You can always make a second pass wiht more cleaning should you desire.


On your outside corners you might consider making them an open V instead of a closed outside corner. It's about a 100 times easier weld to make and it looks purdy

 

Thanks guys for the comments and help.
Filler size and tungsten were 3/32. I dont remember what the alloy was, but it was pure tungsten(green). Material was 1/8in thick and balance was set at 7.0. I just learned to adjust the balance just after welding that thing, a comment from another buddy as well. i will have to get some welds in with turning up the balance.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by jj07 &raquo;</TD></TR><TR><TD CLASS="quote">Thanks guys for the comments and help.
Filler size and tungsten were 3/32. I dont remember what the alloy was, but it was pure tungsten(green). Material was 1/8in thick and balance was set at 7.0. I just learned to adjust the balance just after welding that thing, a comment from another buddy as well. i will have to get some welds in with turning up the balance. </TD></TR></TABLE>

YAY IM UR BUDDY....YAY

 

I just went through the same scenario at work welding some fuel cells (sand drag atv's) and it had been a while since i had welded AL. Those pics you posted look just like mine, referring to the bead shapes and the black stuff all over the place.

Good tip david, i never really tried to turn up the AC balance all the way, mainly because i didnt understand it entirely. My question is, if im set to max penetration, should i bring the overall amperage down at all?

JImmy

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by DESTROYER &raquo;</TD></TR><TR><TD CLASS="quote">I just went through the same scenario at work welding some fuel cells (sand drag atv's) and it had been a while since i had welded AL. Those pics you posted look just like mine, referring to the bead shapes and the black stuff all over the place.

Good tip david, i never really tried to turn up the AC balance all the way, mainly because i didnt understand it entirely. My question is, if im set to max penetration, should i bring the overall amperage down at all?

JImmy</TD></TR></TABLE>

I wouldn't worry about turning the amps down. From start to finish on an AL weld you are going to be dropping amps more as you near the finish and even more as the piece heatsoaks in realtion to mild steel or stainless. It's really a matter of observing the bead and adjusting the heat with your pedal.

 

no critique...... please teach me to weld like that...

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by evans_art &raquo;</TD></TR><TR><TD CLASS="quote">no critique...... please teach me to weld like that...</TD></TR></TABLE>

lol....this guy....he just wants to weld sumtin