Im having some issues on welding the runners to the D Style Plenum. Im using Green Tungsten And having issues on getting the Plenum to form a spot on it so i can weld a gap from the runner to the Plenum.

Also what do you guys use to clean aluminum before welding?
What AMP should i use?
What Size Tungsten? Anything else i should know?

 

What machine?
How thick is the metal?

 

I am some what new to tig welding.I use soap and water with a scotch bright pad or a ss wire brush to clean the aluminum.

 

you most likely arent giving it enough heat. and it wont melt together like steel, youll need to add some filler to it.

 

i was using 150 amps... the machine is Miller Syncrowave 250DX

 

uhh.... yeah dont use scotch brite or soap

use a stainless brush and wipe is with acetone

 

when I weld aluminum, Ill hold my arc, or go back and forth from piece to piece untill the surface of the alum looks like its luquidy, then ill add my filler. after that I dont even really weave just go and dab dab dab. youll see what I mean. like It said you wont fuse two pieces together first like steel.

 

what amps should i use?

Also how should i prep the tungsten, I always feel like im doing it wrong with aluminum

Sometimes i feel like the welds get contaminated because it starts bubbling and

 

dude just use as many amps as it takes to get a nice puddle its that easy...

 

yeah if you clean the oxide of the aluminum good enought it shouldnt be hard at all go get the puddle goin

 

this, or you can see something that resembles 1/2 a puddle on each, and just dip in the keyhole it makes

 

we don't know, we have to have you you have, same machine tungsten. not an exact science with machines, i have seen the exact same machine weld something at 100 that won't even get the arc started on 110 on another.

tungsten just grind length wise as normal to a shrap point such as SS then just lightly stab the wheel to break the sharp part off, then grab a piece of scrap and weld a short bead so you don't include the tungsten fragments on the **** that includes something. i just do that so i see a ball which is probably a bad habbit but w/e.

the bubbling is the metal starting to get hot keep going until you see a shiny puddle

 

make sure the machine is set to AC!

 

Use a 1/8" diameter pure (green tungsten) and sharpen it to a 45 degree bevel or so. Get a block aluminum and form the ball on the end of the tungsten so it's at least the same diameter as the tungsten.

Pre-heat the aluminum if possible (oven) or with your torch.

I suspect you simply aren't generating enough heat. Try 250 amps and give it the wood.

as always prep your metal.

 

stainless wire brush is all i use for alum prep.

when i start a tack weld, i will crank my welder as high as it goes (180) and pump the pedal probably between 150 and 180 to heat up the material... add a drop of filler to start a puddle and keep pumping until it flattens out across the gap. don't know why, but for tacking, i find this works better. once the puddle is started, then just a steady heat control to match the desired bead size.

 

I'd recommend zirconiated tungsten over pure for the syncrowave.