Cast aluminum Tig help

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-Im currently working on a project that consist of mainly cast aluminum. Im using ceriated 3/32 tungsten and am averaging about 150 amps. Ive turned ac balance to 62% which is lower than usual and i still get a bunch of black stuff. The main problem i have is because ac balance is so low the tungsten doesn't last long and i have to re sharpen often. IF i were to go with a 1/8 tungsten will this keep my tungsten usable for a longer period? OR will another type of tungsten be better suited? I am cleaning the cast aluminum with a stainless wheel until bright; i understand the cast parts are just dirty but at this point i am just trying to be efficient. I am using a dynasty 200dx.-Also, if i were to mate two cast aluminum tubes together what method would produce the strongest weld? Gap no gap?Learning the ropes....
Reply:Are you getting the black stuff at the beginning of the weld and then shiny metal as you progress? What's your frequency set to?With respect to gap or no gap, how thick are the tubes and what do they do?-Chris
Reply:Ceriated tungsten doesn't like a lot of cleaning. Try any other tungstenTorchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:Originally Posted by GambleCeriated tungsten doesn't like a lot of cleaning. Try any other tungsten
Reply:3/32" 2%La tungsten sharpened to a point 3x diameter with a small flat.  The tip will ball on it's own, but it should stay fairly small because the tungsten should run relatively cool. 1st on WeldingWeb to have a scrolling sig! HTP Invertig 400HTP Invertig 221HTP ProPulse 300HTP ProPulse 200 x2HTP ProPulse 220MTSHTP Inverarc 200TLP HTP Microcut 875SC
Reply:Holy dumpster diver Super! Punch that Diastiny to 200 cramps and punch it. Cerialated trunkstins is a wimps selectrode. Get some 2% Manthanated large size and go big. While you are at it what alloy is your casting???????? What filler are you using?What do you mean gaps?Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:What kind of cast ? head, block, trans, etc. Cook the crap out of it first then use less cleaning. The more cleaning you use the more crap you will pull out.www.georgesplasmacuttershop.comPlasma Cutter and Welder Sales and Repairs--Ebay storeTec.Mo. Dealer Consumables for the PT and IPT torch's
Reply:Originally Posted by Mr. SmithAre you getting the black stuff at the beginning of the weld and then shiny metal as you progress? What's your frequency set to?With respect to gap or no gap, how thick are the tubes and what do they do?
Reply:Originally Posted by superchargedv8As soon as i light up the black stuff comes up and at times it looks like so much crud comes up it looks like foam if that makes any sense. My frequency is set to 130hz. The tubes are about 1/4" which at most.  They bolt up to a hose that has some stress on it.
Reply:Originally Posted by shovelonHoly dumpster diver Super! Punch that Diastiny to 200 cramps and punch it. Cerialated trunkstins is a wimps selectrode. Get some 2% Manthanated large size and go big. While you are at it what alloy is your casting???????? What filler are you using?What do you mean gaps?
Reply:Originally Posted by mechanic416What kind of cast ? head, block, trans, etc. Cook the crap out of it first then use less cleaning. The more cleaning you use the more crap you will pull out.
Reply:Originally Posted by shovelonBad gas or gas delivery fail.
Reply:Originally Posted by superchargedv8Can i use a map torch to "cook crap out".
Reply:Originally Posted by shovelonCook it out with your weld. The issue is your tungsten and black crap. How is your tungsten at 80 balance? What is your filler?
Reply:Originally Posted by superchargedv8At 80 balance it is fine, i progressively went down to clean more but maybe I'm going about it the wrong way? The filler is 4043 wiped down with acetone before use. Since the part is relatively thin I'm trying NOT to put too much heat into it to avoid cracks.
Reply:Id listen to Shovelon.... not his first rodeo and he's telling you the same thing myself and others would tell you.Miller Dynasty 200DXMiller Spectrum 250DMiller Millermatic 200Bunch of old blue dinosaurs....
Reply:One thing I have found to work well on cast aluminum is lighting up with max cleaning action, and just wash (without puddling the base metal)where you are going to weld, and let the cleaning action of the machine do the "cooking out" for you.  Then wire brush, acetone wipe if you like, reset machine to desired settings, and weld away.  Much cleaner results.
Reply:The best way I have found to clean cast is with a flap wheel. Just knock all that **** off until it's nice and shiny. Welds so much better that wayTorchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:Originally Posted by weldypantsOne thing I have found to work well on cast aluminum is lighting up with max cleaning action, and just wash (without puddling the base metal)where you are going to weld, and let the cleaning action of the machine do the "cooking out" for you.  Then wire brush, acetone wipe if you like, reset machine to desired settings, and weld away.  Much cleaner results.
Reply:Originally Posted by GambleThe best way I have found to clean cast is with a flap wheel. Just knock all that **** off until it's nice and shiny. Welds so much better that way