All i can say is WOW!!!!

I have a newer syncrowave 200. I had to use all of about 185-200 amps to weld this material. I wasn't properly prepared for it, but the customer put it on me and said, i just need it done no matter how it looks because he is going to grind the welds and polish the piece.

My tung and filler rod were way to small for the app. I doubled up on the filler holding 2 pieces at a time bound next to each other. The heat was sooo great i had to keep the filler about 3 inches away from the puddle when i pulled back from a 'dab' and then back into VERYYYY quickly. Turned out in the end better than what i first started off with.

My machine was screaming bloody mary as well as my parents house electric bill. LoL.

This was something I never wanna do again, atleast until i have all the right equipment. But the customer came out of no where and was like, i need this done no matter what.

 

Yea I used a dynasty 300 cranked all the way up, that thing was LOUD

although in hindsight, using helium and DCEN would have worked better.


edit: haha i completely spaced the second paragraph about how you did the filler. lol


Modified by k24em2 at 12:22 AM 1/19/2008

 

Try welding a cyl head from a Mercedes diesel truck. I had my machine wide open using a helium mix and still had to preheat the head in the over to 450F. Burned through 3/32" tungsten like it was cool. Good thing it didnt have to be pretty, just good enough to drill and tap for a new stud.

 

i weld some really thick al sometimes.....you really have to preheat to get any sort of consistent result

 

i used to have to weld 1/4" aluminum rectangular tubing to 1" thick aluminum (clevis mount)
i think i had amperage set to about 230amps on the Syncrowave 250 with cooler.

needed the 230 to get it started. once it heated up could back off on the amperage a bit with the foot pedal. maybe to 75%.

for 1" thick to 1" thick that is gonna take a nice vgroove and quite a few passes. hope you have a cooler, the torch is gonna get HOT

don't forget to cover up your skin cause that will burn you in no time at that amperage. will look like you were at the beach laid out for 24 hours with no sunscreen.

 

I was welding a small 3+ gallon surge tank this past week and i had to pre-heat the heck out of the metal to even get the welding started. I was using an old miller machine my boss just bought. It has a cooler as well. I had the amperage cranked up to 160 amps. I was welding 3/16" 6061. I have never welded that thick of aluminum before. I am used to welding IC piping.

 

can someone please explain alittle better with the dcen and helium? advantages and disadvantages?

 

You know the rule, its always a first time for everything, but where are the pics!?

I would have beveled it and weld it with MULTIPLE passes.

 

Tig-welding-tips - In DCEP:

* 30% of the heat is concentrated in the workpiece
* 70% of the heat in concentrated in the tungsten electrode
* Shallow penetration
* Wide weld area

Tig-welding-tips - In DCEN:

* 70% of the heat is concentrated in the workpiece
* 30% of the heat is concentrated in the tungsten electrode
* Deep penetration
* Narrow weld area


and helium just helps it get hotter.

 

I just throw it in the oven and put it on broil.

I pre-heat with the oven as well as with the welder. I weld in the same spot for maybe 20 seconds to put even more heat into the piece and then I start welding.

basically... you need a bigger welder :-P thus why I want a dynasty 300dx...mmm its only like 4500 used. lol

 

I def dont miss welding alum. I did it with a MIG, a Fronius to be exact. 480volt machine at 160-170 amps, would burn 3/8 and 1/2 really nicely, especially prepped and beveled for a flat bead.

 

To be completely honest, if I had to weld thick (>1/4") aluminum on a daily basis, I would probably buy a push-pull gun and a GMAW machine. I've welded 1/2" aluminum plate with the MM350P and a push-pull gun like it was nothing. Granted, EVERYTHING gets completely covered in aluminum oxide so your jacket, mask, pants, everything is white when you are done.

 

Preheat the son of a bitch and weld in multiple passes. I've done it with a syncro 180 before with 3/32 tungsten and 1/8 filler. You can run a few passes without filller to super heat the exact area you are welding(on top of preheating it)

Helium and DC is cooler though

 

I was repairing a wrecked flat deck with my sync 200 earlier last year.
Cut off the frame rails and built new ones. I was at 185amps and could only weld about 2mins/10. It sucked. I went and bought a spool gun and it was about 10 times faster. Just have to make sure it's set-up perfect.

Then, sold the 200 and bought the dynasty 350. Lucky, as I had to weld a custom intake with a 5/8" flange on it(aluminum). It was so easy.
Pre-heat in oven and weld away. There is alot to be said for the right equipment, but we have all been there before.

 

i've welded 2" thick aluminum blocks with my piddly little 180sd and just preheating the material on a hot plate for an hour. works not bad. also having a 1/8" tungsten helps too.

 

Yea, i smack myself for not preheating it now

 

Yeah, a 200amp machine really isn't enough if you're on any kind of time frame. lol

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by tony1 &raquo;</TD></TR><TR><TD CLASS="quote">Yeah, a 200amp machine really isn't enough if you're on any kind of time frame. lol</TD></TR></TABLE>

wanna trade your machine for my Sync200 and a few bags of popcorn and some KFC straight from the homeland its self?

 

gtibunnyv16;
i understand the how much of the heat transfers to which side as well as a/c is 50/50. i meant just for play i've tried to weld aluminum on dc before and it just didn't work at all. i mean there's absolutely no nice weld pool.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by 9bells &raquo;</TD></TR><TR><TD CLASS="quote"> Lucky, as I had to weld a custom intake with a 5/8" flange on it(aluminum). It was so easy.
Pre-heat in oven and weld away. There is alot to be said for the right equipment, but we have all been there before.</TD></TR></TABLE>

200 amps just doesnt cut it for 1/2" and thicker stuff. Once i got my dynasty 300 i realized what i had been missing. I run the machine on occasion at 280-300 amps without a hiccup. 5/32 tungsten holds up to it pretty good! there is def a lot to be said about the right eauipment.

 

between the syncrowave 180 and the dynasty 350.... BGI DIFFERENCE. Love the extra amps lol

 

How much are the 350's new anyway?

 

I have a dynasty 300, it really isn't quite enough to do 1/2" Al, it'll work but it is a bit underpowered, a dynasty 350 would be perfect.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by ditch_bound &raquo;</TD></TR><TR><TD CLASS="quote">How much are the 350's new anyway?</TD></TR></TABLE>
Around 6500-7000 all up with torch/cooler/etc.