just started playing with aluminum...what do you think?

Tue, 31 Aug 2021 15:50:35 GMT

go to see Welding Machine for just started playing with aluminum...what do you think?

so this is my third session of just playing around with some scrap aluminum while on break at work...what do you guys think?  i think its a little cold, but i may be wrong...go ahead, lay it on me...oh, the material is .100", using 3/32 second rod, machine set at max amps of 165, i dont remember what i had the frequency set at but time at dcen was 78%. Attached ImagesLast edited by punkfreerider; 03-02-2009 at 05:51 PM.Reason: wanted to add another picture
Replyooks pretty nice, Id like to see it a little hotter with less buildup but nice smooth beads.its hard to see but did you wirebrush that first?  It doesnt look like it and if you didnt that could be the reason it looks  a little cold and didnt flow into the bottom piece well.One more thing I noticed, if you look at the starts I it looks like you just bridged the gap between the pieces and didnt melt into the joint.  If you didnt weld it on both sides try to break them apart and see if you got down into it or if its just laying on top.  My bet is that at least at the starts you just layed on top of it.Last edited by sn0border88; 03-02-2009 at 11:41 PM.Have we all gone mad?
Reply:needs more heat, and what does the back side look like? aluminum can look perfect but not penetrate for squat. you should have a 'milk line' on the back side from start to finish:
Reply:Your welds are nice and uniform but I agree with all, they appear cold. You stated that the machine was maxed out, therefore, heat increase is not possible. I think the major problem is the 3/32 filler wire used. When welding .1 thick anything, 1/16 filler, or less, should be used. the problem with using too large a filler is that it takes more heat to melt the filler than the base...3/32"=.093,,,,almost the thickness of base metal.Miller TrailBlazer 251Miller HF-250-1Miller MaxStar 150 STLHyperTherm PowerMax 380 plasmaLincoln PowerMig 180Millermatic 252Miller Diversion 180
Reply:Originally Posted by wagin You stated that the machine was maxed out, therefore, heat increase is not possible.
Reply:Ease off the pedal and add an extra dab of filler at the end.  Every one of those would fail "inspection" because of the craters at the end of the weld.
Reply:Well basically it has already been said wellds were too cold  and you didn't get the fusion you needed for the two pieces and you bead sat ontop. Looks lke it would snap apart fairly easy if you clamped the piece into a vise and hit the top of the two pieces, You said your machine wasn't maxed out so I would set the amps higher and go down a size on the filler. possibily a bit slower on speed as well so your dimes are closer on overlap and smoother appearing rather than looking like they are sitting ontop of one another.Overall not bad  for a "third session".Co-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.&  2 Hypertherm HPR260's Plasma CutterSorry I had a bad stroke but now I am back.
Replyunk,Already been mentioned, but beads look a little cold to me.Can't imagine why.  165A is "more than enough" to weld .10" material.  In fact, it seems quite high to me.  What arc length are you holding?  Personally, I would be using (as opposed to some recommendations) 3/32" filler for that practice run.  I think you'll find that, until you get more experience, that 1/16" filler will present problems with melting before you get it to the puddle.Taking care of the divots at the end of the bead has already been mentioned.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:im holding an arc legnth of about 1/16 to 1/8...thanks for all the input, im gonna practice some more tomorrow, keeping in mind the suggestions...ill be sure to post pics...thanks again!
Reply:so i just clamped that sample in a vice and beat the **** out of it with a hammer...here are the results...a couple tiny little welds on one end of the picture, broke in the weld, so they were def cold, but i couldnt get a couple of them to break...i kinda lost interest in hitting em haha...any input? Attached Images