how do I weld .035 aluminum. ..

admin

I have some .035 sheet I want to butt weld or really any weld. (Tig)I have .040 tungsten, and .035 wire or 1/16 4043 filler. I can't figure out the settings to keep the edge from melting away, fast like. I can run a bead fine away from the edge... Pulse slow or fast? What amperage? Background current? On time? Everlast 250ex.
Reply:Is the .040 tungsten holding its shape or balling up like crazy? Where did you find .035 filler rod? I used 1/16 filler and 3/32 tungsten when I welded some .040 aluminum maybe it was .032. I was using around 65 amps or more I think when it was cold might of even used over 85 amps but can't remember
Reply:Where did you find .035 filler rod?
Reply:its actually .032, I measured it today. The .035 filler is aluminum wire off a 1lb spool.
Reply:Don't tack the very edge, keep your tacks inside a little bit. When you are all tacked up light up on your tack with filler then drift it back quick to the edge, then get the heck out of there as quick as possible. Same deal at the end, put your last dap of filler on the tack and drift it to the edge super fast.I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Tungsten is not balling up, it's staying super sharp. I tried the tack method, but even to tack it the edge disappears before I can get a tac.
Reply:At what amperage is your machine striking the arc? Mine, in AC, strikes at 20A which can be a lot for thin ally.HF 98233 Stick/TigHF  95136 PlasmaEastwood TIG200Eastwood MIG250Damn, I cut it twice already and it's still too short!
Reply:Originally Posted by shaynoakTungsten is not balling up, it's staying super sharp. I tried the tack method, but even to tack it the edge disappears before I can get a tac.
Reply:For really thin stuff, I start the arc on the filler rod, not the material.   Or adjust the up slope to be much, much slower than normal, if that is an option on your welder.  May need to be in 4T for it, also depends on the welder.
Reply:Originally Posted by AxisFor really thin stuff, I start the arc on the filler rod, not the material.   IOr adjust the up slope to be much, much slower than normal, if that is an option on your welder.  May need to be in 4T for it, also depends on the welder.
Reply:Originally Posted by tigmaniacAt what amperage is your machine striking the arc? Mine, in AC, strikes at 20A which can be a lot for thin ally.
Reply:Hello shaynoak, sometimes if you can use a stainless steel backing on your aluminum projects it will allow you to get away from some of the melt-back on the edges of thin aluminum parts. I will try to attach a sketch to illustrate this a bit. Since aluminum and stainless aren't attracted to one another very much the use of the stainless steel will help to better control issues of burn-through. Good luck and best regards, AllanIn the image that I have attached you would clamp the top pieces to the bottom piece sandwiching the aluminum between the stainless steel pieces Attached Imagesaevald
Reply:Just practice good grief man. Thats all it comes down too.I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Im guessing you got the machine set to 250 lol. Either lite up real slow and go from there, and jab in filler when you get in trouble or just practice on 1/16 and brush with stainless brush
Reply:Good idea. I'll try that when I can get back out there.