Tig 1/2" aluminum?

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Quick project,  The bar stock is 1/2" x 4" and the tube is 3/8" wall. all 6061 new metal.Whats the best way to set this up? what it is for is forks on a 2 wheel hand cart that fold up out of the way. Ive never welded any aluminum thicker than 1/4", most that I have has not turned out the best. Ive got a syncrowave 250dx. pure argon, 3/32 and 1/16 fillers. Do I need to jump up to a 1/8" tungsten? amps? Preheat? Tips?Im thinking multiple passes.
Reply:Pic, the piece on the bottom will be longer... Attached Images
Reply:Yes, step up to 1/8" tungsten. Bevel all the edges, and multi pass. 1/8" filler. Maybe put a little torch preheat on it to get your base temp up to 300 degrees or so before you start. Preheating will lessen the cracking around the weld areas, as your base metal will keep its' temp down, and the variation from the weld area to the base metal will very possibly cause some cracking when the weld cools. We get that on our aluminum motor mounts if we don't preheat.And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:I would use a spoolgun if it is an option.Have we all gone mad?
Reply:Originally Posted by sn0border88I would use a spoolgun if it is an option.
Reply:Oh boy...I thought it would be fairly obvious that I didnt intend for you to use one on a sync, maybe he has access to a spoolgun and didnt consider it as an option.Have we all gone mad?
Reply:Either bevel or use 100% helium on Dc- --Gol'
Reply:No spool gun and no helium, im not going to mess around with getting another cylinder to just weld this one little project...
Reply:Preheat preheat and preheat again before you startMiller 330 A/BP Bernard SS coolerMiller cst 250Miller Big Blue 251DCentury 210 Mig (first welder I bought)Hypertherm PowerMax 800Victor torch setRu Fong 31 MilAtlas lathe
Reply:If you are not going to use what most have said (Helium), then good luck.  JohnSMAW,GMAW,FCAW,GTAW,SAW,PAC/PAW/OFCand Shielding Gases.  There all here. :
Reply:Originally Posted by weldgaultIf you are not going to use what most have said (Helium), then good luck.  John
Reply:You can do it with that machine.  Just put a bevel on it, use green tipped tungsten (red if you wind up melting the green), and weld away.  I'd reccomend running the torch over the bevel a few times to preheat it a bit...then get a good puddle going and weld it.
Reply:I might try it tomorrow, Not sure if I will get everything cut and figured out in time though...