Beginning Aluminum

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Hello, I just received a Linconln Precision TIG 185 (free) today, along with a few toungstens, and some aluminum filler rod.I have the machine set up in AC, 35 amps, 3/32nd filler and toungsten (green), as shown by my slide rule.  the material is a very light guage aluminum sheet.The arc is not stable, and doesn't seem to melt the material, but will melt the filler rod.  The melted rod sits on top of the aluminum, similar to dripping solder onto a cold steel plate.Three specific questions1) How much stick out should the toungsten have from the edge of the cup2) what sort of tip should I be grinding3) what are the average canadian costs of toungstens?
Reply:I bet your aluminum workpiece needs to be cleaned more.  Scrub it in one direction with a stainless brush and see if that helps.  It should be bright and shiney.  Make sure you have the angles right with the torch and filler.  Try to make a puddle before you add filler, and when the puddle forms add the filler at a very low angle to get under the reflected heat.  35 amps sounds a little weak, you might also pump up the amps a bit and the arc might stabilize, but that all depends on just how thick the workpiece is.  I have read some posts that complain about the arc stability on this machine...you might check into that if the stuff above doesnt work.Smithboy...if it ain't broke, you ain't tryin'.
Reply:So, i tryed cleaning, no avail.  Now, I don't think I changed any settings, but i've started burning through toungsten like crazy.  What could this mean.I also tryed the reverse polarity on aluminum, but I just tripped the breaker, even at 5a. hmmm...?
Reply:If your tungsten touched the surface of the aluminum you may have really contaminated it.  Regrind it to a point.  If you are running DC you shouldnt be.  AC with high frequency on continuous is the way to go.  Post a picture of the settings, there might be something obvious that I am not thinking of right now.Smithboy...if it ain't broke, you ain't tryin'.
Reply:As it turns out, there is a problem with the machine, and it gets warrentied. (once i find a way to get it to the warrenty shop  )
Reply:Originally Posted by ctardi3) what are the average canadian costs of toungstens?
Reply:Originally Posted by minskYou can buy from aglevtech and they send to Canada with no custom problem.http://stores.ebay.com/Aglevtech-com...ssPageNameZL2/
Reply:As it turns out, the problem was a defective machine.  As soon as I struck a DC arc on some scrap steel, the cap bank let out a cloud of smoke big enough that I couldn't see across the shop (2 car garage).Warrenty is bringing me a new one today.