Aluminum pipe. Marine Industry

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I am going to post some pictures of what the "boss" wants our welds to look like. I would like some pointers on how to get to that point. The pictures of the pipe are anodized aluminum pipe. The pipe we use is 6003 aluminum with 4043 filler using pure argon. Any pointers on setting changes, techniques used, or even using a different gas like pure helium would be greatly appreciated. Even going as far as to getting a machine that can adjust the hertz if needed. 1st pic is of an anodized pipe and where I want my welds to be.2nd pic is the same thing just with the anodized removed.3rd pic is of the machine we use.Lincoln Square Wave 175 TIGLincoln 110v flux core welder (my 1st)Clarke 180EN MIG
Reply:I am getting better at working around the pipe and I understand practice makes perfect. But I also can not get my bead puddle or pattern to mimmic the above pics. This is the only picture I have right now of my welds. I understand that this is a totally different joint and even a different series aluminum. But I just wanted to post it because it let's you know where I stand on my current level of welding. I am far from a pro, but I believe myself to to beyond a beginners level.5052 aluminum using the same 4043 filler and exact same settings and machine. Lincoln Square Wave 175 TIGLincoln 110v flux core welder (my 1st)Clarke 180EN MIG
Reply:If these parts get anodized after you weld, you won't want to use 4043, it does not anodize like the rest of the aluminum. You will want to use 5356 filler for a proper anodized look.
Reply:I would first try to use smaller filler. The spacing on your dips in the last picture are much further than what your boss is looking for. Also, 2X on the 5356 filler for anodizing.Lincoln Precision Tig 185Lincoln Power Mig 256Hypertherm PM 45Everlast 140STSmith O/A
Reply:Just want to point out that there's quite a few different types of "anodizing".   It's kind of a catch all term for a lot of different electro chemical processes.  In general anodizing is broke down into Types I, II and III (and there's a number of sub types to those).   Whether or not you can get a way with welding with out first removing it depends on what type of anodizing it is.   For instance, the pipe in the first picture has most likely been given a really thin layer of Type I or IIB anodizing which is usually not to problematic to weld thru for building certain things.   But other types of anodizing (like a Type III [hard] anodize that's had a dye incorporated with it) almost always require that it be remove before welding if you expect to end up with any where near decent looking results.  Using 4043 filler metal in the type of Marine application (like the OP is referring to) won't be a problem in this case because they're not going to re-anodize the structure after it's welded together.  For one thing very few (if any) anodizing companies would have an anodizing tank big enough to get something like a tuna tower in.   What's usually done in situations like this is to spray some kind of paint or sealer over the welds to protect them and the areas adjacent to them where the original anodized coating has been burnt off from the welding.On smaller aluminum weldments that are going to be anodized after welding (and where the best color match is desired) there it's important to use 5356 filler on 6xxx aluminum base material.   It's my understanding that it's the higher silicon content of 4043 that makes it darken during anodizing and not match the color of 6xxx series aluminum.
Reply:Practice practice and more practice is all I have to say
Reply:The pipe is anodized prior to being bent, fit, and welded. Thank you 4956 for your informative response. I didn't know that about anodizing.I have heard that doing 2 passes is the trick... any truth to this? I was told that doing a small bead penetration pass with 1/16 filler and then doing a cover pass with 1/16 filler to make it look nice is the trick. I just never liked doing a cover pass directly over another...Right now we are using 3/32 4043 filler. I think tomorrow I will experiment with 1 / 16 5356 filler. I'll have to bring it from home since they do not carry it currently at the job site.Lincoln Square Wave 175 TIGLincoln 110v flux core welder (my 1st)Clarke 180EN MIG
Reply:I use 1/8 5356 on anodized pipes works good one pass just have to find you happy spot and practise
Reply:You sound young and impatient. If not your excited about doing a good job. Both require the same response. Slow down. Take it one puddle at a time. Make the first puddle excellent and then make the rest of them the same. Your still just making one puddle at a time. Accuracy first, speed second. You'll get there.Arcon Workhorse 300MSPowcon 400SMTPowcon SM400 x 2Powcon SM3001968 SA200 Redface1978 SA250 DieselMiller Super 32P FeederPre 1927 American 14" High Duty LatheK&T Milwaukee 2H Horizontal MillBryan
Reply:Abec, Can you post a pic of your work if you don't mind?Also, what gas are you using? Are you using an invertor or transformer machine?Last edited by sen2two; 06-13-2014 at 07:10 AM.Lincoln Square Wave 175 TIGLincoln 110v flux core welder (my 1st)Clarke 180EN MIG
Reply:Originally Posted by blawlessYou sound young and impatient. If not your excited about doing a good job. Both require the same response. Slow down. Take it one puddle at a time. Make the first puddle excellent and then make the rest of them the same. Your still just making one puddle at a time. Accuracy first, speed second. You'll get there.
Reply:Originally Posted by sen2twoI have heard that doing 2 passes is the trick... any truth to this? I was told that doing a small bead penetration pass with 1/16 filler and then doing a cover pass with 1/16 filler to make it look nice is the trick. I just never liked doing a cover pass directly over another...Right now we are using 3/32 4043 filler. I think tomorrow I will experiment with 1 / 16 5356 filler. I'll have to bring it from home since they do not carry it currently at the job site.
Reply:I am having trouble getting a clean bead on schedule 40 anodized marine tubing. I just purchased a miller dynasty 200 DX. Just curious what settings anyone is using with this machine i.e. a/c balance, high freq. etc. I am using 3/32 lanthanated electrodes,160 amps and 3/32  4043 filler, and pure argon. Thank you.