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Did some very limited MIG welding a very long time ago, just finished my TIG setup and now getting ready to learn and to become consistent. I'd appreciate feedback for the time being based on photos I'm going to upload.Very first 2 beads today. Fronius Magicwave 230i on 240 v, set to 140 Amp max, AC, rod is 3/32, angled aluminum is 1/8th, grey 3/32" 2% Ceriated tungsten, cup size 8, 100% argon.First bead on left side with 15 CFH, right was with 25 CFH.Any suggestions regarding settings / penetration / gas amount / etc would be great.
Reply:Last weld is on the top left: changed gas flow to 18 and moved tungsten further into the cup.Looks much better but I pulled the torch away before gas flow stopped, contaminating the end (I assume).It takes like 10 sec for the puddle to build at 140 amp, is that normal?
Reply:Turn up the amps. 2-4 seconds to form puddle. You shouldn't need a #'8 cup either. 5 or 6 should be large enough for aluminum.
Reply:hi Crockett. you want to make sure that the material is cleaned with stainless steel brush and wiped with acetone or alcohol. The oxide layer on Aluminum will get in the way of melting the aluminum. the oxide layer melts at 3600* and the aluminum will melt about 1600*. If it's not cleaned it will look like jello inside a plastic sandwich bag. Turn up the amps so you get a puddle in a few seconds, hold the tip of the tungsten about 3/32 above the material and push the puddle. To get used to the process, just try running beads on the material for a bit then add filler to the equation. It does take some patience and practice without doubt.
Reply:Are you applying the 140 amps when you start, is that what the machine is set too and max that can be applied.That angle might cause some turbulences as you approach the up-legLooks like a good start.
Reply:Thanks for all the suggestions.I put a cup 6 on, that seem to keep the bead narrower. I don't have a 5, will be ordered tonightI also increased amps to 155. That resulted in too much penetration and sagging through to the other side.140 amp is not the max of the welder, its the max setting.I cleaned the rod and the angle aluminum with acetone but didn't use a wire brush. Will add this too my list. Thanks for explaining the difference in temperatures.So I think I found out what I did wrong. I didn't use the pedal properly. I didn't give it enough amps when starting a weld, hence it took too long and put too much heat buildup into the material, and once I had a puddle I didn't ease off enough. So I put it back to max 140 amps and use the pedal accordingly.I need to work on my angle, I'm always trying to see as much as possible and the angle is too steep, and speed it up a bit once the puddle is there.The marked bead was my last try. Why is there an indent on the last blob?
Last edited by crockett; 12 Hours Ago at 03:19 PM.
Reply:Good. That is what i was asking, were you applying max set amps.
Reply:
Originally Posted by crockett
Thanks for all the suggestions.I put a cup 6 on, that seem to keep the bead narrower. I don't have a 5, will be ordered tonightI also increased amps to 155. That resulted in too much penetration and sagging through to the other side.140 amp is not the max of the welder, its the max setting.I cleaned the rod and the angle aluminum with acetone but didn't use a wire brush. Will add this too my list. Thanks for explaining the difference in temperatures.So I think I found out what I did wrong. I didn't use the pedal properly. I didn't give it enough amps when starting a weld, hence it took too long and put too much heat buildup into the material, and once I had a puddle I didn't ease off enough. So I put it back to max 140 amps and use the pedal accordingly.I need to work on my angle, I'm always trying to see as much as possible and the angle is too steep, and speed it up a bit once the puddle is there.The marked bead was my last try. Why is there an indent on the last blob?
Reply:Aluminum requires a different process/mindset compared to steel...it's almost like a polar opposite in many ways. Take the cup size and double it to get the ballpark CFH setting. Set max amperage for 1 amp per thousandth of an inch of stock thickness plus 20% or so. Hit the pedal HARD after the arc stabilizes so you get a puddle in 1-2 seconds...any longer and you're putting too much heat into the work which will travel and get ahead of you. As soon as you get a puddle you have to MOVE and ease off the amperage a bit as you go. At the end ease off the amperage even more, do a swirl or circle while adding an extra dab or two of filler to prevent the crater.Check out my bench vise website: http://mivise.comMiller Syncrowave 250DXMillermatic 350P with XR AlumaProMiller Regency 200 with 22A feeder and Spoolmatic 3Hobart Champion EliteEverlast PowerTig 210EXT
Reply:
Originally Posted by M J D
It's a crater. Back off more on your pedal and dip in more filler as you taper off. |
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发表于 2021-11-2 15:51:29