I'm having a lot of problems welding aluminum. It seems like sometimes I weld it fine and other times I suck. I think it may have something to do with my prep process since Aluminum is a little more picky than other metals. I'm using a sync 200, I wire brush the ends of the tube with a SS brush used only for Al, and then I wipe it down real good with acetone.

Syncrowave 200, gas set around 20cfh, using the normal size gas lens with 3/32" zirconiated tungsten and a number 8 cup. I think balance is around 7 or so, I've tried playing with it and it doesn't seem to help.


I'll try and get some pics up later if you think that will help, but really I just want to know how you guys prep.

 

if its a non critical part, sometimes I dont prep at all, and still usually get a decent weld. If it's something serious (structural) I'll wire brush/wire wheel with a stainless brush.
Usually I'll just leave the welder on auto balance.

Maybe something related to the acetone? Contaminated? Try wire brushing w/o the solvent rinse down afterward?

 

what color is the end on the tungstein?

Green is what you should be using

and make sure it doesnt get contaminated even a little bit of contamination will effect bead performance

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Nick Z32 &raquo;</TD></TR><TR><TD CLASS="quote">what color is the end on the tungstein?

Green is what you should be using

and make sure it doesnt get contaminated even a little bit of contamination will effect bead performance</TD></TR></TABLE>

Zirc is brown, and is preferred over green for aluminum

 

my zirconiated is white?

 

balance should be lower like 3 for more cleaning

 

Bump im in the same boat some days with my PT185

 

I think most of the times it really depends on the metal and where its from. Cast aluminum can be a pain at times.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by narfdanarf &raquo;</TD></TR><TR><TD CLASS="quote">my zirconiated is white?</TD></TR></TABLE>

depends on brand...usually its brown

 

I was always taught on a non inverter machine, you can use red for anything.

 

you can but its not going to look pretty

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Nick Z32 &raquo;</TD></TR><TR><TD CLASS="quote">you can but its not going to look pretty</TD></TR></TABLE>

BS , been welding with a red tungsten, nothing else , for about 4 years straight now. Don't believe everything you read.

 

Use a torch.. heat it up, let it cool then weld.

Of course prep the surface first.. i.e. emery cloth, scotch brite, wire wheel

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by 91jdmhatchback &raquo;</TD></TR><TR><TD CLASS="quote">you calling that pretty? you must have beer goggles on or some ****.


now i'm not the greatest at welding al, but i also don't go on h-t and brag up my "ok" welds as pretty.


now i know you own a business so in the future you should refrain from posting bad welds so ppl don't think you a n00b.

just my $0.02

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

The weld on the top, yep. That pic was over a year old. For someone to say you can't get good looking welds on AL with a red tungsten, is bull ****. Then again, this site is full of bull ****. As for posting pictures and making people think I'm a noob, my work speaks for itself, I'm where I'm at because of it.

Another weld done about a year ago, when I first started on aluminum. Not the best looking weld I have layed down, does it look like ****, by far.

Like I said, to say you can't get a good looking aluminum weld with a red tungsten is bull ****, and if you want to believe it, your fooling yourself.

As for the original topic, do a little research, search for a guy name engloid. One of the best welders out there, always stood by the claim, no need to switch to anything else besides a red tungsten. I'll stick to what he preaches.

I found some entries from Engloid

"Engloid
11-29-2005, 05:03 PM
I think all these different tungstens are just a way for companies to get more money out of your pocket. It doesn't work for me...I use 2% for everything."

Engloid
11-29-2005, 05:17 PM
Engloid
2% what?


oops... thoriated. The cheap stuff.





Modified by 90blackcrx at 8:25 AM 8/11/2008


Modified by 90blackcrx at 8:32 AM 8/11/2008

 

Those welds look great, 99.9% of people will be very happy with those. No need to see whos dick is bigger.

 

90blackcrx - Your aluminum welds are improving alot. Those weld doesn't look bad at all. Just a little more consistancy, but other then that it looks fine. (as you mentioned, those are 1 year old welds) Hell, I improve within a day, yet alone 1 year of welding aluminum. People are sometimes ********, as you notice. lol.

But yea, I use 2% Red for everything, and by far, the only tungsten I will ever use for Alum/Steel etc..

Tony1 -

 

Steel wool ,True green

 

If you're doing XRAY aluminum work, use zirc

 

i was told to use green stripe on thinner al........ i dont have tranning just a community college class (which doesnt really count)

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by i drive a honda &raquo;</TD></TR><TR><TD CLASS="quote">i was told to use green stripe on thinner al........ i dont have tranning just a community college class (which doesnt really count) </TD></TR></TABLE>

not on inverter machines but thats all I used on transformers.

 

 

Dave, can you post some pics of "proper" Al welds? Id like to see what you produce. Im not trying to be a dick or call you out, just curious to see what they look like since Im probably doing it wrong. I learned how to weld from reading, asking questions and seeing what others produce.

Im with Tony, I weld with 2%, get pretty decent looking welds and Ive never had one fail. Ive tried Zirc and truthfully, I could never get a good looking weld with it. So now I have a $100 box of it sitting, collecting dust. If you have technique tips, Id love to hear those also.

 

Sure I'll see if I can't make a couple test coupons or retrieve some pictures from a camera.

As far as technique tips go, what kind of machine are you using and what kind of material do you want to weld (grade and thickness?).

 

6061 ranging from 1/8" to 16ga. I have a Lincoln Precision 185. I use 2% thor. rounded at the end by grinding and then balled slightly. Im going to borrow my friends SLR to get some good pics of my aluminum welds. Pics should be up in an hour or so.

Also, to get back to the thread. To clean, I clean with an acid for 10 mins, rinse with water. Spray it down with acetone and scrub with a stainless brush. Wash one more time with acetone, I seem to always get a nice clean looking puddle.

 

Does your machine have adjustable fequency?