Problems adding filler when TIGing aluminum

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I am trying to teach myself to TIG aluminum, and continue to have trouble adding the filler.  Every now and then I get it, but I can't tell the difference when it works and doesn't, so I'm asking for any advice you all can give.    The set up I was practicing with tonight is:  Miller Syncrowave 250DX, set to Max amps 225, 100% Argon, AC, 3/32 2% Lanthinated tungsten.  Welding 4" aluminum box tube, 1/8" wall,  tried with both 1/16" and 1/8" filler rod.     The problem I'm having is that when I get a puddle started and try to dip the filler, the filler starts to melt away from the puddle(the arc is jumping over to the filler maybe?), and I get a large glob on the end of the filler rod and nothing added to the puddle.  I have tried holding the torch at a different angle to the puddle, but it doesn't seem to help.  What is a good way to add the filler?I should add that any welding skills I have are all self-taught, so it's not safe to assume I know anything.
Reply:Sounds like your tungsten is too far from the puddle.  Try about an eighth of an inch and feed your rod to the edge of the puddle and not between the arc and the work.  I like the 3/32 rod myself.
Reply:I weld with a Miller 250DX...For Aluminum I always use 1/8" 2% Thoriated (Red) Tungsten, 100% Argon at about 15cfh. For 1/8" thick Alu. I use 1/16" 4043 rod and set the peak amps between 175 and 200. I don't use all of that amperage when welding but I like to have a little reserve to bump up if I have to. I'm probably welding with around 130-150.On the 250DX there is a knob to the left of the Polarity selector called "AC balance"...where do you have this knob set? The lower the number, the more cleaning action the AC wave will provide. The higher the number, the more penetration. The # 3 is called "balanced". This is when the AC wave is equally positive(cleaning) and negative(penetrating). I usually run this setting at 6 to provide a little more penetration but make sure your base metal is CLEAN.It sounds like you're not being patient enough with the aluminum. Hold the arc on the base metal(s) a little longer and wait for it to build up some heat first. When you see the shiny puddle start to form, then add your filler.Here is a sample of a weld I did with these exact settings. 1/8" aluminum, 1/8" 2% Red Tungsten, 100% Argon @ 15cfh, 190 Max amps, Balance control @ 6.Last edited by ZTFab; 08-22-2006 at 09:49 AM.http://all-a-cart.comWelding Cart Kits and accessories
Reply:Sounds a bit like your are trying to add filler from the wrong angle.  The filler should be added at a much lower angle than you are holding the torch at.  Maybe 20-30 degrees (or so) from the surface of the workpiece...push the filler in under the reflected heat from the torch.If your filler and torch look like this \  /, or like this \|, you will melt your filler before it gets to the puddle.  Lower the angle of the filler.Smithboy...if it ain't broke, you ain't tryin'.
Reply:The speed which you advance the filler into the puddle with is another thing to consider after getting the angle right.  In some applications, specially if your filler is on the small side for what you're doing, you have to get it in and out really fast to avoid the problem you're having.
Reply:Thanks for the tips.  I will try some more tonight.  My AC balance was set at 4, I'll try bumping it up to 6 and see what happens.  Unfortunatly I can't use acetone to clean, I work in a food plant and they are real picky about having chemicals without specific approval.  I'll definately play with the the angles some.
Reply:i like to pull back the toch just a tad as i add and always add the filler to the front leading edge of the puddle almost sliding along the work till it hits the puddle and at a low angel as said above. a good hit with a stainless steel brush will realy help with the cleaning.see picred is filler add it to the front edge as you go if you are getting blobs you mised the puddle, or it was not ready.good luck keep us posted Attached Images summer is here, plant a tree for mother earth. if you dont have time or space, sponcer some one else to plant one for you.feel free to shoot me a PM or e-mail me at [email][email protected] i got lots of time.
Reply:A little more practice with some of your advice in mind helped a lot.  Still need practice, but I can see the improvement.  Thanks.
Reply:TIG takes time dont be impationt, you will get it.8^)) aluminum is the hardest to master so hang in there and you will see more improvement each time. its best if you are having fun at it insted of fighting for it, stay relaxed and it will come in time. summer is here, plant a tree for mother earth. if you dont have time or space, sponcer some one else to plant one for you.feel free to shoot me a PM or e-mail me at [email][email protected] i got lots of time.
Reply:nice drawing..but my torch is at about a 30 degree angle to the work...but nice drawing..how do you do that?...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.