Aluminum TIG/ Tungsten ????

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I can weld aluminum fine but I have a problem with the tungsten melting.  It dances around on the end and if I dont catch it in time it falls on to the work.  I am using a Miller syncrowave 250dx with a weldmark 20-25 torch.  I am using the largest cup for this torch with a 1/8" tungsten and the gas set to 35-40 cfm. Also using a hand (finger) control, if that really makes a difference to anyone.
Reply:Try using red end tungestion..All I ever use is 1/16 or 3/32" on everything I ever weld..Sharp point..And turn your gas down to around 10-15 SCHF...Your just wasting gas now.....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:I am using a 2% red end tungsten.  I have also tried the green end pure tungsten with no luck.  I had read in a fabrication book somewhere that a higher gas flow was required for aluminum.  Gas consumption is not a real concern to me as I rarely weld aluminum, but it sure pisses me off when I cant do it properly.  Should I be warming up the aluminum before hand.  My most recent project was 1/4" thick.
Reply:The only thing that will cause that is wrong polarity or to much current..  That is called tungsten spitting and will do wonders to an xray.  JohnSMAW,GMAW,FCAW,GTAW,SAW,PAC/PAW/OFCand Shielding Gases.  There all here. :
Reply:one question.. what is the difference between the "red end" and "green end" tungstens? chemical composition?Thanks!Later,Andy
Reply:1/4" thick can be done with 150 amps no problem..Let it get good and hot before adding filler..Or pre heat with a torch before welding.....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:Originally Posted by weldgaultThe only thing that will cause that is wrong polarity or to much current..  That is called tungsten spitting and will do wonders to an xray.  John
Reply:Originally Posted by aczellerone question.. what is the difference between the "red end" and "green end" tungstens? chemical composition?Andy
Reply:Originally Posted by aczellerone question.. what is the difference between the "red end" and "green end" tungstens? chemical composition?Thanks!Later,Andy
Reply:Originally Posted by junior636Must have too much current then, I am welding on AC so the polarity isnt an issue.  Probably not waiting long enough for the metal to get heated up and making up for that with current.  I had assumed this was my issue but just thought I might be missing something else.
Reply:Here are some 3/32 RED tungsten at 150 amps with 55% cleaning or 55% + electrode and 45% - .  I have had 1/8" RED ball and fall off using 65%+ electrode doing aluminum at 150 or so amps too.I agree, there is no practical use for Green or Pure tungsten.  Its old school.  DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by pulserAWS lists the max AC current for 1/8" pure tungsten at 180 amps, and 1/8" thoriated at 250 amps.  That is for "normal" AC, balaced wave, 1/2 cycle electrode neg. and 1/2 cycle electrode positive.  If you adjust your balance for more cleaning, electrode positive, the max. current will be lower.On 100% DCEP, a 1/8" thoriated will only handle 40 amps max.
Reply:This place is really helpful I am glad that I found the site.  I run the welding department at the shop I work for which only consists of 3-5 guys.  I dont know much about the technical aspects of welding, I am one of those guys who just figures things out but doesnt always know all the terminology.  I have learned a lot from this site already just today.  We dont weld aluminum very often at the shop if we do its just something small for maintenance or personal.  But I cant wait to try out some of these things you guys have suggested.  Thanks for all the replies fellas.
Reply:I think his problem is that he has to much electrode positive. I get that if i'm set too high for cleaning. Try turning the ac balance to around 65 on the dynasty. i think you'll see dramatic improvements. --Gol'