aluminum tig welding / heat settings

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in my class we have a miller dialarc hf-p and we use it for aluminum tig welding most commonly 1/8th plate sheared to about 6". but a kid in my class decided that it would be fun to turn the heat all the way up to see what happened. it totaly obliterated the 2 plates. my question is why would a machine have that much power what is the highest you guys have ever turned any of your machines? cuz we also have stick welders that go over 2 times the highest ive ever turned it up. and it doesnt make sense to me because if its that thick you would just bevel the end right? not turn the heat up right.
Reply:Originally Posted by himsa169... a kid in my class decided that it would be fun to turn the heat all the way up to see what happened. it totaly obliterated the 2 plates. my question is why would a machine have that much power what is the highest you guys have ever turned any of your machines?
Reply:Originally Posted by TensaitekiNot all the aluminum in the world is 1/8" thick or less. Try repairing some heavy aluminum casting with only 200 amps, I dare ya'. It doesn't matter how much you bevel thick aluminum, when doing heavy sections you'll want just about every amp you can get out of the machine, especially since not everything can be preheated enough to help.Sure, you can bevel really thick material and weld it with little-bitty 1/8" electrodes. But do you have any idea how long it takes to fill up a 2" deep 60 degree bevel with 1/8" rods? I do, the answer is 'bloody ages'. For heavy stuff you'd tend to want to use bigger electrodes, and higher amperages, for more reasons than time savings.Further, most big stick welders can also be used for arc-gouging. Even small arc-gouging electrodes need relatively high levels of current to work well.
Reply:Copernicus? Really, where did that come from? What does any of this have to do with heliocentric theory?Anyway, I didn't mean to come across as 'snippy' and I'm sorry if you misunderstood my tone.As far as filler size, I've personally only taken AC TIG up to just over 300 amps and used 1/8" filler rods with no problem. With proper arc length, torch angle, and filler angle, you shouldn't have problems at even 300 amps with filler as small as 3/32" 'burning up.'It would also help if you told us what amperage 'all the way up' is. Are these 300 amp machines? 400 amp?I'm sure others here have TIG'd at higher amperages than I and would be happy to share their experiences and techniques (assuming they don't have to worry about being called by the names of random renaissance astronomers).Visit Tensaiteki.com
Reply:Originally Posted by himsa169in my class we have a miller dialarc hf-p and we use it for aluminum tig welding most commonly 1/8th plate sheared to about 6". but a kid in my class decided that it would be fun to turn the heat all the way up to see what happened. it totaly obliterated the 2 plates. my question is why would a machine have that much power what is the highest you guys have ever turned any of your machines? cuz we also have stick welders that go over 2 times the highest ive ever turned it up. and it doesnt make sense to me because if its that thick you would just bevel the end right? not turn the heat up right.
Reply:Originally Posted by himsa169in my class we have a miller dialarc hf-p and we use it for aluminum tig welding most commonly 1/8th plate sheared to about 6". but a kid in my class decided that it would be fun to turn the heat all the way up to see what happened. it totaly obliterated the 2 plates. my question is why would a machine have that much power what is the highest you guys have ever turned any of your machines? cuz we also have stick welders that go over 2 times the highest ive ever turned it up. and it doesnt make sense to me because if its that thick you would just bevel the end right? not turn the heat up right.
Reply:BTW, you had better have thin skin if you want to post on these forums, we are basically all professionals who do this day in and day out, and we KNOW what we are talking about so sit back and learn something.Last edited by SR20steve; 01-16-2011 at 07:06 PM.
Reply:Originally Posted by TensaitekiCopernicus? Really, where did that come from? What does any of this have to do with heliocentric theory?Anyway, I didn't mean to come across as 'snippy' and I'm sorry if you misunderstood my tone.As far as filler size, I've personally only taken AC TIG up to just over 300 amps and used 1/8" filler rods with no problem. With proper arc length, torch angle, and filler angle, you shouldn't have problems at even 300 amps with filler as small as 3/32" 'burning up.'It would also help if you told us what amperage 'all the way up' is. Are these 300 amp machines? 400 amp?I'm sure others here have TIG'd at higher amperages than I and would be happy to share their experiences and techniques (assuming they don't have to worry about being called by the names of random renaissance astronomers).
Reply:Originally Posted by Donald BranscomWhat you did was dangerous and could have ruined a $5,000 dollar machine and maybe even killed you . It only takes 1 amp to kill you!!!When you are welding aluminum it is not the thickness that is so important - it is the total SIZE of the weldment that can soak up all that heat. Square inches giving off all the heat.The bigger the weldment, the more amps it will take with aluminum.Read that twice.So when you applied full power to those small plates with a torch that was probablya wp20 which is only rated for 150 amps ,anything could have happened.It depends how many seconds.If the torch connections melt then the fluid would spray all over you and you will be sitting in a pool of water with a 250 amp torch in your hand.If that had been a welding machine you worked for and paid for, would you have tried that experiment????If the torch gets too hot the first thing that happens is the ceramic cup turn white then it will crack.
Reply:Originally Posted by SR20steveHoly crap, I think you just busted a long time industry standard that states more metal requires more heat! So since your welder at 150 amps will weld .125 AL all day, you can weld any thickness of aluminum with just proper joint prep...this is pretty breakthrough info here. Im glad that  a welding school student has figured something out that a lifetime of welding engineers failed to discover.You anger me....seriously go back to school copernicus. You have allot to learn still, you obviously have NO clue about welding. And giving bad feedback to Tensaiteki for giving you sound feedback makes you look like more of a tool...
Reply:btw sr20 ha i just had a guy pay me to weld up turbo tubing for his sr20. So obviously some people think i know a thing or two about welding (not saying im pro or anywhere near a pro if you read any of my other posts you would know that) im just trying to learn more then my teacher has taught such as his terrible information to go vert down with 7018 rod but i came on here seeking more info and by other people on this site that may or may not be "pros". so im going to quote myself and jay o from the vertical welding thread and just read it once twice or in donalds case read it three times since he obviously mis read my post claiming that i would do such a stupid thing.       jayo stated"If the purpose of going to school is to become a professional welder, then welding will be vert up. If your looking to avoid vert up then quit school and go do something else. Every place that is worth working at will test you and if you can't go up then more and likely you would not be allowed to finish the test, muchless be hired. About your sub, it look as if somebody has gotten LAZY . If would need proof then get your hands on some books from Lincoln Electric and start reading."part of my response"yes im going to school to become a "professional" not that i think school makes you a pro cuz i no alot of idiots with a degree. but anyhow i always do vertical up..."and after that post it was agreed with that school doesnt necessarily make you a pro so i would like to ask you have you learned everything you know from a professor at school? didnt think soas quoted by you " seriously go back to school copernicus. You have allot to learn still, you obviously have NO clue about welding." and also said by you    "sit back and learn something."now why would i do that "sit back and learn somthing " when your just going to come off as a wise *** trying to be cool just because you know more then me in this certain subject. and you clearly state "go back to school" first off im still in school so how do i go back to something im stil involved with? and why would i want to "sit back and learn something" (assuming you mean sit back on this site and learn something) if you claim i need to be in school to get any clue about welding. Given the circumstances of my welding class you put me my hands on work and portfolio work against any other kid in my class and i guarentee you my work will triumph everyone else. Considering im the only one with a binder, im the only kid to get above a 75 on our last project. huh a project that involved vertical welding no where would i learn the proper technique to do that o yea by the other guys on here who dont act sarcastic torward people like me trying to learn. Because they and you all know at one point YOU knew just as much as me. and ill add im the only kid who has been paid for the work i did. so let me put it this way ussualy no one pays you for your work considering they asume i got all the supplys for free steel, welders, and tools (although i do use my own tools) and we are learning so they dont expect the best work. well may i add i have been pay for building 2 plow frames from scratch aluminum tubing for a turbo and 2 trailers so obviously the customers very satisfied to pay me knowing they have no obligation to pay me. so even if all of you belive i know 0 about welding i have paying customers and isnt that what it all boils down to? you know you would not go out there every day and bust you *** for nothing but the satisfaction that you know more about welding then the average highschool kid in a welding clas would you?Last edited by himsa169; 01-16-2011 at 08:48 PM.
Reply:popcorn anyone? himsa169 you need to chill. in welding you need a thick skin and clearly you haven't grown one yet._______________________OF COURSE I DON'T LOOK BUSY... I DID IT RIGHT THE FIRST TIME
Reply:I wont add to this drama. But I will say that I dont ever like to have any tool maxed out. Meaning I dont want to be at the operational limit of my tools. Mainly because of my safety, and in a welding machines case, its safety. Welding thick 6061 aluminum with a 180 machine is done but not ideal because it will be maxed out. I have done it when necessary, its just not good practice.UA Local 598
Reply:Originally Posted by WHughesI wont add to this drama. But I will say that I dont ever like to have any tool maxed out. Meaning I dont want to be at the operational limit of my tools. Mainly because of my safety, and in a welding machines case, its safety. Welding thick 6061 aluminum with a 180 machine is done but not ideal because it will be maxed out. I have done it when necessary, its just not good practice.
Reply:Originally Posted by trouble007popcorn anyone? himsa169 you need to chill. in welding you need a thick skin and clearly you haven't grown one yet.