What I'm doing wrong, alu&tig problem.

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The problem is black matter in puddleI have brand new Esab 2200i esab linkBut I don't think that it is manufacturer related so I post it here.Here is Link to my picturesI have cleaned the square pipe with stainless brush, filler rod is cleaned with sand paper, I use rotating sandingdisc to sharpen tungsten and its color of gold as manufacturer suggests. But problem is same with green and red tungsten.Running puddle with no filler, its just fine, no black stuff, but any time, any setting I can think of, adding the filler makes those black spots and it is driving me crazy.any suggestions? Tungsten is out of the cup by the lenght of the pencil shape, and the cup is 7 size.
Reply:You answered your own question.  Look at the last pic.  100 amps, 125 Hz, 50%.  I hope the 50% means wave balance.  Your base metal or filler is dirty or contaminated.  The 80% one shows way more stuff in your weld.  20% + and 80% - wave.  Clean the base metal, or your filler and try again.  Hz is not going t make much difference.  If its too high, the arc will be narrow and impede cleaning of the base metal.Is your sandpaper ALUMINUM OXIDE?  That is some thing you don't want in your weld.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:if any thign use acetone to wipe the filler. i dont sand mine ,just wipe it down
Reply:After long nigt of surfing the forum I stumbled same advice here, not to use sand paper.For those picture sandpaper only is used wiping the filler rod, It was first time I used it on filler, and rotating sanding disk for the sharpening. Same problem is on every piece of aluminium I had tryed, some brand new,some scrap, I try to save the new aluminium for projects.Can Heat make that also? The best run is made last and the item is getting hotter. I try that last setting to brand new aluminium and acetone it and filler, lets see.
Reply:Clean your filler with acetone and rag ONLY. Clean your material with a Stainless wire brush ONLY. Then try it...John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Originally Posted by MicroZoneClean your filler with acetone and rag ONLY. Clean your material with a Stainless wire brush ONLY. Then try it...
Reply:Watch the puddle as you weld.  If the contamination shows up when you dip, then you know its coming from the filler.  I had some old filler and no matter what I did to it, It added black stuff to my puddle.  I threw it out.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:I dont get the whole filler cleaning thing, cleaning it with sandpaper is crazy.  Adding sanding grit to aluminum is one of the easiest ways to get crap in your welds.  Ever try welding aluminum that was cut with an abrasive cutoff wheel?Keep your filler in the tubes until you have to use it and you will never have to clean it.Have we all gone mad?
Reply:Originally Posted by sn0border88Keep your filler in the tubes until you have to use it and you will never have to clean it.
Reply:I do not know what you mean about the tungsten being out the length of a pencil point. At most the tungsten is out 3/16" to a quarter. Unless you have a crotch to weld in an acute angle. If you have the tungsten out that far, you could get those results. If you have oil or contamination on the back of the plate and penetrate well, and you probably did. You can also dredge that up too. That is why especially with aluminum, old aluminum extrusion is not your friend, when welding it. Sincerely,William McCormick
Reply:i use a sctchbrite pad followed by acetone to clean my filler works well
Reply:Are you sure you're  not pulling the filler rod out of the gas flow between dips?  Keep it in the gas flow untill the weld is done and gas stops flowing.   If it gets out of the gas shield when the tip is hot, it oxidizes, then you bring that oxidation back into the weld on the next dip.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:sometimes maybe your base metal is dirtier than you think. The pictures show that the hi freq.  is working, but the particles are too big to be cleaned out..02
Reply:That's contamination plain and simple. Most likely as they have told you either dirty filler or dirty workpiece. This can also be caused by bad shielding gas, but I have only seen that once in 30 years. And yes it almost drove me up the wall before I figured it out. Always clean your workpiece with a stainless brush, and if you do any grinding or sanding you must do this after. I always wipe my rod with a clean rag dampened with alcohol (works for me) and if the material is greasy or oily I do the same to it before I brush it. This can also be caused by puffs of air getting to the weld before it cools, and the slightest breeze will cause that.The difference between art and craft is the quality of the workmanship. I am an artist.
Reply:I stand behind what I said.Have we all gone mad?