Aluminum welding issue

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So I am having a strange issue trying to weld aluminum. I've had plenty of practice with aluminum, so I do know how to do it. I have a Lincoln Precision TIG 225 that is about 6 years old and has never given me any issues. I recently replaced the torch and lead, and got a new pure argon cylinder around the same time. I've had a few porosity issues here and there on steel (never on stainless), but it seemed the cap on the torch keeps coming loose. Once I tightened the cap and ground out the porous weld it went just fine.Now skip to some aluminum welding. I have a brand new sheet of 5052 .080, using 3/32 tungsten (have tried red and brown with same results), tried everything between 60 and 100 amps, used the auto balance setting, set it to all cleaning, and all penetration, and everything in between. Keep getting the same results. I have cleaned the metal thoroughly with several cleaners, brand new rags and I replaced the stainless brush I use for aluminum with a new one and still no luck. I am getting corrosion in the weld, bad. If I can even get a bead to start, it looks dull gray, and has black spots in it. Most of the time, I can see the weld start to turn black and start bubbling as I try to heat it with the tungsten, the gas/arc will start to flash bright green like I dipped the tungsten, although I have not. I have checked all the fittings from my tank to the welder, the few inside the welder I can get to, and all the fittings on the torch lead, and I can find no leaks. I can feel the gas coming out of the torch. I've used gas flow settings between 14-20 lbs and it makes no difference. I contacted the manufacturer of the torch and they said they have not had any issues like mine, and to contact my gas supplier to see if it is bad gas. So I called them earlier today, they said they have not had a batch of bad gas in years, but they are willing to exchange my bottle and test it to see if it is bad gas. I have attached a picture of what the weld is doing. What do you guys think?Also I should note, there where a few spots that started welding fine, so I tried to put in about a half inch weld. Some of them worked, sometimes it went porous half way through the weld. Could it be bad gas and the aluminum is just making it more noticeable since it is a finicky metal to begin with?Thanks for any help. Attached ImagesLincoln PowerMIG 215XTLincoln Precision TIG 225Hypertherm 300
Reply:Originally Posted by Twisted Minis I've used gas flow settings between 14-20 lbs and it makes no difference.
Reply:Sorry, 14-20 CFH, not sure where I got lbs.Lincoln PowerMIG 215XTLincoln Precision TIG 225Hypertherm 300
Reply:Originally Posted by Twisted MinisSorry, 14-20 CFH, not sure where I got lbs.
Reply:Did you try it on some flat scrap of the same sheet?If it works there, but not on the outside corner - you're having gas splitting issues.  You would increase flow to fix.Note: I have not had that particular problem yet, but I've heard of it and that was the fix in that case.Dave J.Last edited by MinnesotaDave; 07-09-2013 at 09:01 PM.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:Originally Posted by MinnesotaDaveDid you try it on some flat scrap of the same sheet?If it works there, but not on the outside corner - you're having gas splitting issues.  You would increase flow to fix.Note: I have not had that particular problem yet, but I've heard of it and that was the fix in that case.Dave J.
Reply:Originally Posted by MinnesotaDaveDid you try it on some flat scrap of the same sheet?If it works there, but not on the outside corner - you're having gas splitting issues.  You would increase flow to fix.Note: I have not had that particular problem yet, but I've heard of it and that was the fix in that case.Dave J.
Reply:Originally Posted by SquirmyPugI have had that, more flow didn't help. Just had to use a really short stickout and arc length to prevent the problems.
Reply:@ TwistedMinus - concur with MN Dave's recommendation to rip some welds in the flat position as a baseline.  If blackness still present with sketchy puddles, then perhaps gas contamination is the culprit.  Differential diagnosis will aid in ruling out any unknowns.SideNote:  4043 or 5356 filler?  Both will work.  Trying to understand the whole story.Last edited by ManoKai; 07-09-2013 at 09:30 PM."Discovery is to see what everybody else has seen, and to think what nobody else has thought" - Albert Szent-Gyorgyi
Reply:Can you go back to your old torch and lead?  Or borrow another torch for a test?  Can you borrow a different tank of argon? Trying to exclude as many variables as possible...
Reply:I am using 4043 filler, and have used different batches and sizes. Using a #8 cup and gas lens. I will try another test piece in the flat position. I can use my old torch but not the hose, it split and started leaking gas.Lincoln PowerMIG 215XTLincoln Precision TIG 225Hypertherm 300
Reply:What torch did you buy?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 bought a #17 from HTP America. I've had good luck with their products before, specifically their gas lens kit on my Lincoln torch. I emailed the owner to see if they have had any issues like this before, I assume I will hear back tomorrow.I cut two small pieces off of a scrap and welded them together without cleaning it at all. It welded fine, albeit like I did not clean it. So I think that rules out the gas issue. so I went back to the work piece, same issue. Turned CFH up to 22 and it will actually weld now. Toward the center I had okay results, but it is still corroded. Toward the edge I am having better results than before, but not what I would consider good. Its difficult to form a puddle at all, and when it does I can see it corroding before I add filler. I can still try my old torch, or turn up the pressure some more? I am using maybe 1/8" stick out on the tungsten, and about the same arc length. Should I shorten that up? Or am I going to need to purge this thing?I attached pictures of my results. Attached ImagesLincoln PowerMIG 215XTLincoln Precision TIG 225Hypertherm 300
Reply:Glad to hear you're making progress I've seen people lay a piece of angle next to the weld to help trap the gas.Or just try 25 cfhDave J.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:Is there any chance its anodized aluminum?? I'm running out of ideas Airco Ac/Dc 300 HeliwelderMillerMatic 200 (stolen)Miller Maxstar 150STLMiller AEAD200LE (welding and generating power) Hobart MIG
Reply:Originally Posted by SquirmyPugIs there any chance its anodized aluminum?? I'm running out of ideas
Reply:Excellent ! Dave J.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:It's not the torch that's the issue. I have sent you a pm.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:Take a flap disc and smoothen out the sheared off edges so they are nice and shiney and hit the outside edge for about 1/4" around the weld area then report back.....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:Zap, what kind of flap wheels do you use? I haven't had good luck with them, they tend to gall up the aluminum. I generally use a 3M scotch brite pad on a 2" air grinder.Lincoln PowerMIG 215XTLincoln Precision TIG 225Hypertherm 300
Reply:Originally Posted by Twisted MinisZap, what kind of flap wheels do you use? I haven't had good luck with them, they tend to gall up the aluminum. I generally use a 3M scotch brite pad on a 2" air grinder.
Reply:Was the metal in front of your old torch was prepped and cleaned?OzDynasty 200DXMiller 210 Spooly
Reply:No, I had not cleaned that side yet.Lincoln PowerMIG 215XTLincoln Precision TIG 225Hypertherm 300
Reply:It's not the metal that's the issue.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:Hmmmmmmmm  looks cold to me?  The reason I say this is the way the weld is bunched up and not wetting out......Almost sounds like it is whatever you wiped it down with because you said it had a GREEN color when you attempted to start a puddle?Last edited by B_C; 07-12-2013 at 06:30 PM.  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig RockGamble, what's your theory?
Reply:It's a bad power cable in the torch. Contact the place you got it from and say you believe it's bad and you would like a new one.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