Making Aluminum Lava??

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This has been an off and on problem welding aluminum with a Lincoln Weld-Pak 155 (converted to gas).    Most of the time the welds, ugly as they are, come out fine.  The sound is what I want, a "frying bacon" crackle sound.  Then, for no apparent reason, the noise changes to a high pitched hiss and the resultant welds look like gray rough lava rock.  There is little or no penetration also when this happens.    Usually I grind off the "lava" and weld the spot again.I'm using the highest voltage setting and 7 or 8 (of 10) on wire speed.  I'm pushing 4043 wire and running 100% Argon at better than 30psi.  Any thoughts out there?There are no small projects
Reply:i thinkyoiure hitting duty cycle   coud be wrong...but its my guess  good luckIF it Catches...Let it Burn
Reply:Maybe, you're losing the shielding gas?... Is it also porous?We need to protect Freedom of Speech, otherwise, how would we know who the A-holes (like me) are.
Reply:Can't be that.   The problem occurs at any time, even right after startup.   I don't think, because of my weld, look, weld, cuss, weld, look, weld, look, cuss...method, I've even come close to a duty cycle limit.There are no small projects
Reply:Originally Posted by BBchevy396Maybe, you're losing the shielding gas?... Is it also porous?
Reply:well,  like bb said shielding gas,  or cleaniness of joint... like even right before you start...perhaps theres other considerations im missing... any pictures?IF it Catches...Let it Burn
Reply:hmmm,  yeah that could be,  well I thinkin it could be...BB you know more about wire feed,  what your thoughts?   I think the solenoid could be the culprit or a short in the elec line between the trigger and hte solenoid??IF it Catches...Let it Burn
Reply:4043 wire...you might be trying to weld a 60series aluminum, which would cause problems.Owner of Welding Wiki,The free wiki based resource for weldor's around the world.http://www.weldingwiki.comWe have cookies!
Reply:Originally Posted by ctardi4043 wire...you might be trying to weld a 60series aluminum, which would cause problems.
Reply:4043 is fine for 5052, and 6061... I'd make sure the gas is flowing.  I fought with my miller 250 long ago... erratic preformance.. turned out to be a bad gas regulator/valve.it would flow at start-up... then slloowwwwly peter-out. Not consistently though.. I'd check the gas ... yup.... got gas! Very frustrating! finally i took out the wire, held the trigger, and yup, it would slowly fade and almost quit! Changed regulator and Wha-la! fixed.  Check that baby, no matter what the gauge says.We need to protect Freedom of Speech, otherwise, how would we know who the A-holes (like me) are.
Reply:Now, I've been told that you can't go down in alloy with wire...maybe i'm wrong.Owner of Welding Wiki,The free wiki based resource for weldor's around the world.http://www.weldingwiki.comWe have cookies!
Reply:I will say this much when BB speaks the redneck listens  IF it Catches...Let it Burn
Reply:5356 is great for 60 series, a bit stronger, but 4043 is better against cracking....even recomended, for 6061. It is softer than 5356  and wets better.  In my experience, here on the pacific coast, I get LOTS of projects with old, crusty, corroded, saltwater eroded alum, and 4043  seems to tolerate more crap.    It is not for welding 5086 alloys though .... good way to get cracks. too much silicon. Use 5356.If you have a piece of plate, of unknown alloy.... use 5356.  If it just won't weld... try 4043... the do some testing.Last edited by BBchevy396; 01-01-2006 at 11:48 PM.We need to protect Freedom of Speech, otherwise, how would we know who the A-holes (like me) are.
Reply:Over the years I have picked up refilled bottles of argon that had contamination.  This will really foul up a weld.  I'm not shy about taking it back.  Try a different bottle of argon.  Sometimes the weld shop will refill the bottle you bring in from a battery of bottles and don't take the time to purge the lines.  I must say that this is very rare.
Reply:Originally Posted by imagineerThis has been an off and on problem welding aluminum with a Lincoln Weld-Pak 155 (converted to gas).    Most of the time the welds, ugly as they are, come out fine.  The sound is what I want, a "frying bacon" crackle sound.  Then, for no apparent reason, the noise changes to a high pitched hiss and the resultant welds look like gray rough lava rock.  There is little or no penetration also when this happens.    Usually I grind off the "lava" and weld the spot again.I'm using the highest voltage setting and 7 or 8 (of 10) on wire speed.  I'm pushing 4043 wire and running 100% Argon at better than 30psi.  Any thoughts out there?
Reply:It's the rocky stuff.   I set up my welder with an extra pressure gauge inline between the regulator and the fittng on the solenoid.  Then I set my video camera to be able to record both the extra gauge and the gauges on the regulator.    I started recording and welded until it made lava twice.   From my cussing on the video recording, it was easy to see when the lava occured.   The guage from the regulator to the solenoid stayed at 30 psi but the extra inline gauge dropped to below 5 psi each time the welds went to crap.   The MIG welders here at work use flow meters (the glass tube with the little ball that goes up & down) and the welders claim they never have any problems.    I'll switch over to one of those before my next project involving aluminum.I forgot to add that I also rigged a small panel light to the solenoid neutral lead and to ground to indicate when the solenoid was on or off.   That ruled out a bad solenoidLast edited by imagineer; 02-02-2006 at 08:53 AM.There are no small projects
Reply:Originally Posted by imagineerThis has been an off and on problem welding aluminum with a Lincoln Weld-Pak 155 (converted to gas).    Most of the time the welds, ugly as they are, come out fine.  The sound is what I want, a "frying bacon" crackle sound.  Then, for no apparent reason, the noise changes to a high pitched hiss and the resultant welds look like gray rough lava rock.  There is little or no penetration also when this happens.    Usually I grind off the "lava" and weld the spot again.I'm using the highest voltage setting and 7 or 8 (of 10) on wire speed.  I'm pushing 4043 wire and running 100% Argon at better than 30psi.  Any thoughts out there?
Reply:it sound like your welder is on DC when you weld with a aluminum with a tig it shood be on AC. If the welds come out like gray rough lava rock then its on DC or you have the wrong gas if you want to get a much nicer weld you shood pre heat the aluminum o and you olny need about 10-15 psi of gas anything more is just a wast  unless you are outside with some windLast edited by gian1500; 02-02-2006 at 11:06 PM.
Reply:Originally Posted by gian1500 it sound like your welder is on DC when you weld with a aluminum with a tig it shood be on AC. If the welds come out like gray rough lava rock then its on DC or you have the wrong gas if you want to get a much nicer weld you shood pre heat the aluminum o and you olny need about 10-15 psi of gas anything more is just a wast  unless you are outside with some wind