whats wrong here

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Millermatic 210 with spool gun  1/4" 6061 wire wheeled clean, 5356 wire .035", pure argon.  I tried 3 settings, started with recomended setting on the welder, then went up one and down one...all 3 yielded similar results.  tried 15 - 30 on the gas flow.  weld is very dirty, and rough, kinda pitted...  whats my problem here.  Its strong as I beat the piss out of it, bent it back on itself and the weld held, but UGLY.  Argon tank is probably 5-6 yrs old, would this matter?  BTW...white residue everywhere!  Like it snowed on my mask...so much i had to wipe it off to see out of it!Last edited by tnc110; 01-17-2011 at 08:45 PM.
Reply:Your picture needs to be re-sized so it doesn't cut your text off. Hard to read and answer a question when not all of it shows. You still have time to edit; maybe a half hour.
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Reply:i would start by checking gas connections, then try 4043 wire, then try another bottleDynasty 200DXPassport plus w/ spoolmate 100victor 315c oxy/(act and prop)Miller digital elitemilwaukee power tools
Reply:use a SS wire brush.( clean buy hand). a wire wheel can bury the oxide layer back into the base metaldont think gas gets old but maybeidealarc 250/250 ac-dc tigidealarc 250/250 ac-dc tig #2 used for sticklincoln sp100hh125dual arbor grinder polisher30 yrs of hand tools52 pitch blocks 6p-26prake gauge -pitch gaugeG&D prop repair 918-207-6938Hulbert,okla 74441
Reply:just looking at the picture i see the material is no where close to being clean enough. When welding aluminum the base has to look like it just rolled out of the mill. If  your bottle is that old it is possible it has created moisture in the tank and has caused a film of rust inside. get your base cleaner, still having problems, change bottles.
Reply:I agree......clean by hand and use 4043 wire! Wipe clean with acetone or alcohol after you brush it.StephenMillermatic 251Miller Syncrowave 200Miller 30A SpoolgunHypertherm Powermax 30Etc., etc., etc.............Cancer Sucks!
Reply:Did you cut the metal with a plasma cutter before welding, If you did try cleaning the edges with grinder before welding. The plasma edge will contaminate your weld.
Reply:ok guys...today i switched tanks, switched to 4043...welds are MUCH cleaner.  All is well wtih the settup, just need a bit more practice.  couple more questions...under the lid of the welder it has settings for 4043...I'm welding 6061...how do the two differ on heat and speed?  Also how can i test my gas flow/regulators.  I have a ball type and a needle type...I noticed the ball type, the ball was bouncing up and down in the tube...im guessing something is wrong here!
Reply:not sure but I think the 4043 settings are for 4043 wire and based on the thickness of your base metal
Reply:the needle doesn't give a real steady coverage stick with the ball. far as the bouncing goes your probally need to change your difuser and tip. also check for leaks in machine and lead.