yet another noob TIG aluminum critique request

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I have been trying to teach myself TIG welding on aluminum.    I have already done a few hours worth of beads on flat metal (although the results below maybe don't show it) and am trying to progress on to something more fun and useful.Below is a picture of my efforts to do a butt-joint weld on two 1/8" 6061 aluminum pieces, using 3/32" 4043 filler rod and pure argon, with a Diversion 180 set to 135 amps: I welded the joint from right to left.  My concern is that I was not seeing weld penetration thru to the bottom of the joint:I was using probably 80% of the pedal for the first 2/3rds of the joint, then cranked it up to nearly 100% for the last 1/3rd to see if I could get full penetration.   Still didn't quite seem to get there, although you can start to see some deformation along the backside.   (And the end of the joint sucked, just about melted it through.)I should be expecting to see full penetration on such a simple joint, right?   Any\all critiques and tips welcomed.thx,Jay
Reply:I doubt 80% of 135 is going to be sufficient for that.  You need more amps.  Be careful welding on that plywood.__David Hillman
Reply:You forgot to list what your flow meter was set to.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:Flow meter was set to 15cfh.   Yeah, the plywood gets scorched once in awhile.   I am still scrounging around for a thick piece of sheet metal to use a poor man's welding table.135 amps not enough?  Hm....the suggested amperage guide on the front of the welder shows about 130 amps for 1/8" thick metal.    So I figured I was going above and beyond with 135.    It felt like at 135 amps I could burn through pretty quick if I'm not careful...EDIT:  I mis-read the welder amp guidance...max suggested amerage for 1/8" thick AL is about 145 amps.   Ok, guess I was running a little too cool - but that doesn't last long on such small pieces.Last edited by jay98014; 12-10-2011 at 11:00 PM.
Reply:Wait until you see the key hole before you add the filler wire. Dang it man.  It's just welding! Two turn tables and a microphone.
Reply:Originally Posted by jay98014135 amps not enough?  Hm....the suggested amperage guide on the front of the welder shows about 130 amps for 1/8" thick metal.    So I figured I was going above and beyond with 135.    It felt like at 135 amps I could burn through pretty quick if I'm not careful...EDIT:  I mis-read the welder amp guidance...max suggested amerage for 1/8" thick AL is about 145 amps.   Ok, guess I was running a little too cool - but that doesn't last long on such small pieces.
Reply:Originally Posted by PangeaWait until you see the key hole before you add the filler wire
Reply:Originally Posted by Drf255 I'm currently at around 2000 inches
Reply:I was taught to leave a small gap between a but weld.  In these pics it looks like the two pieces were touching (I could be wrong), is that correct or should there be a small gap to start?Just picked myself up a TIG and going to try to get back to where I was when I learned a number of years ago.
Reply:Unless you start with a gap between the two pieces you probably won't get that "Penetration" your looking for......Some sort of weld prep is necessary......Talk to a PIPE WELDER....Also make a dab just before you end your weld and tail off so you don't leave a crater  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Originally Posted by that'll_buff_outThat's what she said ......
Reply:Nice looking weld for only a few hours of welding.. i would say the first half is what you want to go for....after that ur piece started to get too hot and that's y u lost the look of the weld. miller has a nice app on the app store for free that helps with that...other then that tho.. as you weld use less heat with your foot as you go...because the piece is getting hotter and hotter u need less heat to keep your pool going and you will keep a nice consistent looking weld...Keep up the good work bro.
Reply:Originally Posted by Drf255Newbie here as well, but I've come to learn that this is the key to proper Aluminum penetration.   I can't remember the guys name, but DSW replied to one of my posts with a reference post showing beautiful TIG illustrations.