Best way to Keep Tungsten Sharp for long time when welding Aluminum? 2% lanthinated

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we use the followingLincoln PT275 machine at 180amps (transformer machine at 60 hz)Water cooled torch with 3/32 blue 2% lantinated tungstens.040 filler rod 4043 alloyButt welding 3/32" thick square aluminum tube that is about 1x1/2" in sizeWe can do about 50 of these butt 1" long welds before the tungsten becomes annoyingly balled up and we change it out. What is the best technique to keep the tungsten sharp, and thus the arc focused? When I started out I saw several youtube videos that suggested balling up the tungsten, this was the stupidest advice I ever got.  Welding IMHO is so much easier with a sharp tungsten and focused arc. would a larger diameter tungsten help? Is there some way to cool the torch more to keep the tungsten from balling up? I have about 20 tungstens and just pop a dull one out and put in a sharp one. When all of them are dull we resharpen them all at once.
Reply:# 1 change the type of welder you are using to an inverter..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Due to running AC for aluminum you're not going to be able to prevent some balling of the tungsten.  Even Lanthanated.Jody's comparison may help to explain.http://www.weldingtipsandtricks.com/...lectrodes.htmlMM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:50" of weld with a transformer welder sounds great.180A sounds a bit much for a 2.4mm tungsten especially with a transformer machine. I would go 3.2mm if I were to weld at this amperage for a longer time.As DSW said an inverter would help since it gives you greater control on the waveform, balance etc.
Reply:180amps with a .040 filler wire ?How many feet per second are you feeding the wire?
Reply:I used a Lincoln 275 Tig machine when I was in school. Never did like the machine for the facts you state. Since you are stuck to 60 hertz the tungsten would ball and the arc would wander.
Reply:This is a 3/32" 2% lanthanated tungsten after 200" on 0.125" thickness 6061. I have a Lincoln square wave TIG 175 (baby brother to your machine). My machine doesn't have balance control, but Terry said he believes my machine is fixed at 70% EN. Would you say your tungsten looks worse than this? Maybe try turning your balance control on the 275 up a bit (more EN)?2% lanthanated electrode by Zanconato Custom Cycles, on FlickrThis is how it was initially prepped. 2% lanthanated electrode by Zanconato Custom Cycles, on FlickrLast edited by zank; 06-08-2014 at 06:36 PM.
Reply:If you have balance control use less cleaning. With 72% EN I can run a 1/16th electrode at 140amps and it still has a nice point. Or point ish. I'd have to take a pic to show you.Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:Zank, it's pretty much pointless to make suggestions on how he can improve the welds. He's stated before several times he doesn't do the actual welds. The welds he's shown in previous threads shows the people doing his welds really can't weld alum either. He just blows off the suggestions that the people who are doing the welds 1st need to improve their skills.He just wants to buy some new "magic" gizmo that will solve all his problems vs actually hiring someone who knows what they are doing..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Originally Posted by AKweldshop180amps with a .040 filler wire ?How many feet per second are you feeding the wire?
Reply:Originally Posted by zankWould you say your tungsten looks worse than this? Maybe try turning your balance control on the 275 up a bit (more EN)?
Reply:Originally Posted by DSWHe just wants to buy some new "magic" gizmo that will solve all his problems vs actually hiring someone who knows what they are doing.
Reply:Originally Posted by DSWZank, it's pretty much pointless to make suggestions on how he can improve the welds. He's stated before several times he doesn't do the actual welds. The welds he's shown in previous threads shows the people doing his welds really can't weld alum either. He just blows off the suggestions that the people who are doing the welds 1st need to improve their skills.He just wants to buy some new "magic" gizmo that will solve all his problems vs actually hiring someone who knows what they are doing.
Reply:so in summary I will try the following:1. change AC balance2. use large 1/8" diameter tungstenPer the PT275 instruction manualAC BALANCE CONTROL – The potentiometercontrol permits AC wave balance adjustment fromMax. Penetration (~85% negative wave) with thecontrol at Max. full CW position, to Max. Cleaning(~65% positive wave) with the control set near minimumCCW position.• Full minimum CCW position is the Auto Balanceposition which is indicated by the Green panel lightturning on. This feature automatically provides theproper amount of cleaning and penetration for normalAC TIG welding• The mid position is the Balanced position (~50%positive and negative waves).• The Balance control is only functional if the machineis set to AC polarity and TIG mode.I had mine set to auto mode I'll try turning it fullly clockwise to it is 85% negative and see if that works. the aluminum we use is pretty clean mill finish stuff.
Reply:Originally Posted by SquirmyPugCareful DSW, you might make the Ignore list club like me and Dave.
Reply:It seems an oversized tungsten can keep a smaller ball, but focusing the heat is all about torch angle and arc length anyway. I'd probably use 1/16" 5356 filler at that heat. Use the machine you have. Keep using it.Last edited by Brazin; 06-14-2014 at 08:51 PM.SqWave 200Millermatic 190Airco 200 ACHypertherm PM45Boice-Crane Band SawVictor O/A
Reply:Yes the 1/8" tungstens and the Ac balance adjustment helped a lot! IMO just as good as the inverter lonevity 160sx i have. Kind of a wierd comparison, but they are the only two machines I have used.