Welding Pop Cans ???

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You guys that have sucessfully welded pop cans........is there any trick to this???I have tried this to no avail. I can weld .040 aluminum but the can thing stumps me. I wire brush the cans and still no luck. I get a little wetness going and then my filler rod balls up and then I blow a hole in the can. This is with a sharp tungsten and at a max of 12-15 amps.Any suggestions???
Reply:Try 25-30 amps. Puddle on one can and dip. Puddle on the other can and dip. Then add filler to connect the two.I can do them ok, but never got all the way around without a hole because I don't give it time to cool.And the 186 isn't as good down low as the 221. Drill a hole in the bottom of each can too.Torchmate 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:I did it with my old Dialarc 250 HF, I haven't tried it with the Dynasty. The Dialarc is 60 HZ sine wave 50/50 balance. A very small thoriated(.040") helped control arc wander, arc would go horizontal to the full diameter of the can otherwise. With inverter this shouldn't be needed, 1/16 should do. I think the Dialarc was way off in amperage, at 40 amp I was using full pedal. Clamped and cleaned cans, start 1/8" from the joint, form a puddle dab a bit of filler. Move to the other side of joint, repeat. Jump back and forth enlarging the dabs until they close the gap. Foot pulse focusing on the center of the joint & the center of the wet bead. With 1/16" 4043 work your way around. Keep the arc out of the joint and on the thicker deposit of filler metal. Don't be afraid to create a pulse with your peddle.
Reply:One thing I did wonder about. Should the cans be rinsed and allowed to dry first? If you think about it this seems to make sense. .......heating  a can that has soda in it might create fumes affecting the shielding gas........just spit balling here.
Reply:There are a bunch of threads about pop cans, a couple I remember about razor blades.....I think once upon a time Zap welded tin foil too. You may find more of the info you need by a search. Have fun and post the pics.If you don't want to stand behind our Troops, feel free to stand in front of them.
Reply:Originally Posted by rahtreelimbsOne thing I did wonder about. Should the cans be rinsed and allowed to dry first? If you think about it this seems to make sense. .......heating  a can that has soda in it might create fumes affecting the shielding gas........just spit balling here.
Reply:Did this a few years years ago. Miller Econotig turned down as low as it would go, 3/32" pure tungsten, 1/16" 4043 filler...
Reply:Originally Posted by LimitedSlip7Did this a few years years ago. Miller Econotig turned down as low as it would go, 3/32" pure tungsten, 1/16" 4043 filler...