tig welding 1/2" aluminum, Miller 330 A/BP i need to be schooled

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First post so please don't beat me up too bad, I still know how to read though.here are the specs:Miller 330 A/BP tig welder, water cooled torch, foot pedalapprox. 250AHF continuous AC60HZ3/16 2% Ceriated (yellow) Tungsten  20CFH Heleium/Argon 5356 3/32 filler rodtrying to butt weld 2- .5"x2.5" pieces of aluminum extrusion here is my practice piece from to pieces in our scrap bin, I simply used acetone, stainless steel brush, wiped the filler rod with acetone n welded awayhere is the pieces that I really need to look good.  so I used acetone, wire brush, acetone, pre-heat with oxy/accyt torches, wiped my filler rod, tungsten re-sharpened, and welded away... or I thought.  sparks flew, one pop so I stop. grooved it out with carbide bit, acetone, brush, acetone preheat, re-sharpen tungsten n try again.  this is what I ended up with.  ive noticed the hotter it got the worse it got. is it the aluminum??  I'm pretty sure the scrap pieces are kieser, and the pieces I need to look good are penntex, im pretty sure penntex is a recycled aluminum extrusion, and I am not sure about kieser.  but im not a professional and ive had enough girlfriends to know that im the one making the mistake.  any help would be appreciated, thanks one more pic, this is another weldment I had to do
Reply:but im not a professional and ive had enough girlfriends to know that im the one making the mistake. any help would be appreciated, thanks
Reply:Looks like a gas, or ground issue to me. If the tube is not vented it will blow air up into your weld.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:its all flat stock, except the last picture which that weldment has already been machined and shipped out.  but it took way too long to make it right, I know I can make them look good but I know that its not the looks, its the strength.  Ive read about having the ground wire coiled and it will make things worse, but it wasn't coiled, im reading on gas flow right now...  I downloaded an app on my smartphone called "Magic Wand"  but in fine print it says "time of magic may vary"
Reply:Im on lunch only looking from my phone, but i see color in that aluminum, hence, i dont think its aluminum bud. Unless its just my small phone screen and a reflection in the pic.I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Well that's answers part of my question,  as soon as I start seeing a puddle I can see it getting dirtier without adding any filler, so its gotta be in the torch??  I'm just puzzled how I can go from one piece n lay a great bead then go to something different n splat...  I've already threatened it verbally n hasn't made a difference, I've tried pure tungsten, even worse, tried 2%theriated n not any better, tried pure Argon even worse.Sent from my DROID RAZR HD using Tapatalk
Reply:Check your gas flow with this.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:You are using a #8 cup?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:Funny how your original test piece was very good.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:#7 cup, where did u get that fancy tool??  N yes I've thrown many tools across the shop trying to achieve that weld, n of course Bossman seen that weld and expects all the welds to look similar, I didn't spend nearly the amount of time cleaning n prepping for the practice piece. The feeling of failure n disappointment in myself is growing.  Sent from my DROID RAZR HD using Tapatalk
Reply:In the pic your metal has a purple tint to it. Are you sure its aluminum? Go back and weld on the first piece and see if alls good.I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Test piece other side I also mig welded it Test piece not cleaned, wire brush, not preheated Actual frame, cleaned, wire brushed, preheated, same settings Sent from my DROID RAZR HD using Tapatalk
Reply:Im with Mike, I don't think that's (weldable) aluminum. If it's recycled, who knows what they have mixe into it.Regards,RobGreat Basin WeldingInstagramBlue weldersRed weldersMy luscious Table DIY TIG Torch cooler
Reply:Well...  I've filled out complaint forms verbally many times...  Bossman and the designer say after all the processes it takes to make recycled aluminum into sellable aluminum that its aluminum, so... it comes down to me and I'm doing something wrong and I need to figure out what.  Lucky for me Bossman checked on me right after the mig n seen that I only moved 3" to the left to weld the frame n that nothing could have or did change.  I'll figure something out.  It just sucks when I see so many pretty aluminum welds n the only way I can get close to that is to pull 3 year old aluminum from our scrap binSent from my DROID RAZR HD using Tapatalk
Reply:The portable flowmeter is available from Netwelding.com.http://netwelding.com/prod02.htmYour #7 cup will work with 20cfh. Do you know for sure what the alloy is?  If your test pieces weld clean, and your extrusions do not, then yes, point a finger at the alloy. Don't know.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:6061/T6511Sent from my DROID RAZR HD using Tapatalk
Reply:And this is how the aluminum looks when it comes in our shop, of didn't use to be like this but I guess the price is right and I need to adjust myself to learn how to weld this *shrug* Sent from my DROID RAZR HD using Tapatalk
Reply:You say it's 1/2 thick and you are only using 250? amps??Not nearly enough.I have the same machine and run it on "Kill" everyday.Heat Heat Heat Heat!!!!The more the merrier at first and then that's where pedal finesse comes in.Now about your lack of cleaning.Acetone..STAINLESS steel brush for ALUMINUM ONLY..Clean rags.Clean the weld area with the brush and acetone until it gets real shiny..Then do it again.Trust us on this....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Ok my bad, I did the math n its set between the 135-435 range n dial is at 60 so I figure around 315??  What size tungsten? I've been using c-fold towels, I wasn't sure if I could use a rag, didn't know if it would smear the dirty stuff it wiped up from the first joint that I cleaned.  Should I use shop towels? T-shirt? Obviously nothing that has been washed yet.  Should I still preheat it? Should have clean it after the preheat? And yeah I've already went thru 5 s.s. brushes thinking they picked something up or I dropped em.  I'm feeling better about this now since u have the same setup n run her wide open.Sent from my DROID RAZR HD using Tapatalk
Reply:Just a thought. Maybe your 3/16" tungsten is choking off your #7 cup?Try a #8 cup or go down to a 1/8" tungsten?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:Will the 1/8 hold up to that much?  I don't have any #8 cups but tomorrow I could try m get my hands on some Sent from my DROID RAZR HD using Tapatalk
Reply:Does this help:Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:I use 3/32" RED END tungsten on EVERYTHING.Sharpen to a point and let it ball up by itself..When the ball gets bigger than the OD of the tungsten grind it again....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:MN Dave,Might I ask what application you are using?Jerry30+ yrs Army Infantry & Field Artillery, 25 yrs agoMiller 350LX Tig Runner TA 210, spool gunLincoln 250/250 IdealArcESAB PCM 500i PlasmaKazoo 30"  vert BSKazoo 9x16 horiz BSClausing 12x24 lathe20T Air Press
Reply:Originally Posted by storemanMN Dave,Might I ask what application you are using?JerryThanks Dave,  Still trying to  get familiar with the awesome resources available through this site.Jerry30+ yrs Army Infantry & Field Artillery, 25 yrs agoMiller 350LX Tig Runner TA 210, spool gunLincoln 250/250 IdealArcESAB PCM 500i PlasmaKazoo 30"  vert BSKazoo 9x16 horiz BSClausing 12x24 lathe20T Air Press
Reply:Originally Posted by zapsterI use 3/32" RED END tungsten on EVERYTHING.Sharpen to a point and let it ball up by itself..When the ball gets bigger than the OD of the tungsten grind it again....zap!
Reply:Originally Posted by SquirmyPugMy machine hates thoriated tungsten on AC. It spits all over and makes a mess, its the only machine I've had trouble using thoriated for aluminum. I've used other machines for tig, both Lincolns and Millers and never had any problem with thoriated
Reply:Any pointers on hertz settings??Sent from my DROID RAZR HD using Tapatalk
Reply:I use to wire brush aluminum but personally found my weld quality went way up when I stop wire brushing. Most of the time your just smearing the crap into the aluminum. Simple Green or hot soapy water works well as well as acetone and denatured alcohol. I never wipe my filler either,simply not necessary for 98% of aluminum welding. JmoOn your machine the hertz are not adjustable, 60 hertz it is.You have ac balance and 70% is usually fine.Last edited by Showdog75; 02-12-2014 at 05:48 PM.
Reply:Originally Posted by RodKnockinAny pointers on hertz settings??Sent from my DROID RAZR HD using Tapatalk
Reply:Yeah I'm retarded, I have no idea why I was thinking it was a hertz dial, maybe cuz Bossman was talking about it., the dial was set at 60 so I bumped it upSent from my DROID RAZR HD using Tapatalk
Reply:Whoah, I just laid the best bead on that frame!!!  And that was with argon, tomorrow I'll hook the helium back up, thanks everyone I appreciate all of ur info n tips, just wish I could get this much help in everyday life.Sent from my DROID RAZR HD using Tapatalk
Reply:[QUOTE=Showdog75;3728211]I use to wire brush aluminum but personally found my weld quality went way up when I stop wire brushing. Most of the time your just smearing the crap into the aluminum. Simple Green or hot soapy water works well as well as acetone and denatured alcohol. I never wipe my filler either,simply not necessary for 98% of aluminum welding. JmoShowdog75Do you think the same approach might apply to oxy/acet aluminum welding?  I have a lot of 6061 structural extrtusions left from my store construction 13 years ago which I would like to learn to use.  I know gas welding AL is a long learning experience but, at 70, I've got the free time.....if only the f-ing weather would cooperate.  Snowing again.Most of my extrusions are about 3/32 thick.JerryLast edited by storeman; 02-12-2014 at 07:28 PM.Reason: clarity30+ yrs Army Infantry & Field Artillery, 25 yrs agoMiller 350LX Tig Runner TA 210, spool gunLincoln 250/250 IdealArcESAB PCM 500i PlasmaKazoo 30"  vert BSKazoo 9x16 horiz BSClausing 12x24 lathe20T Air Press
Reply:Forget the helium and stick with argon. Helium is way harder to get nice consistent welds and it's WAY to expensive to waste doing general welds. Save it for something super thick.