ESAB 2200i tig help

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I have used this machine before and had great success welding Aluminum for dog crates. I can't figure out what I am doing wrong. AC ,20cfm Argon, 3/32 green Tungsten electrode, starting  from 40-125 amps on a foot pedal I am blowing out and melting the Aluminum without getting any puddles going in 1/8" x 1" Aluminum square stock on a but joint. Anyone know what I am doing wrong? 1/2 wide melted gouges in the test coupons with a bit of black contamination on the top. I am so close to picking up a Miller Diversion 180 at this point. Frustrated doesnt even begin to describe where I am at Esab  Mig 200i Caddy Esab Tig 2200i ac/dc water cooled Miller Diversion 180Lincoln HD 110v weldpack
Reply:Same tank of Argon or a new jug?Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Could be your tungsten on that particular type of machine, others will chime in soon. Sent from my SCH-I535 using Tapatalk 2I.B.E.W Electrician and Damn Proud of It !!!! .Virtus Junxit Mors Non Separabit http://www.shrinershospitalsforchildren.org/
Reply:Originally Posted by HundhausAnyone know what I am doing wrong?
Reply:I will try to get out tonight to get a pic or two of what the mess I am making looks like. I have  a bunch of green tungsten but I do have a few reds yet to be opened. I may give it a shot with the reds tonight. Thanks guys for all you help from a newbeeEsab  Mig 200i Caddy Esab Tig 2200i ac/dc water cooled Miller Diversion 180Lincoln HD 110v weldpack
Reply:Anodized material will do it also.Kinda melts under the thick oxide layer, then falls out. Gas problems also.  Totally screws the pooch on aluminum while steel still remains OK.  It's amazing the amount of arc instability and contamination bad gas can create.Have you tried s gas lens yet?  I get by with 8-10 cfh on aluminum with a 9 series torch and a small lens.As stated above, try your arc out on a small test piece.  Swirl with no filler and see if you get a clean puddle with pure white etching.  Also try some different aluminum you know isn't anodized or treat the aluminum with some Easy Off oven cleaner before acetone and brushing.What's your EP/EN ratio set at?I'm on LI if you wanna come down and try a different machine.  I have both bad and good gas.  Use the contaminated stuff on steel.Last edited by Drf255; 05-30-2013 at 05:56 AM.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Check this outhttp://weldingweb.com/vbb/showthread.php...light=AluminumTA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:i have tungsten issue on my esab 161. i believe its the blue labeled stuff, seems to cause odd arc'ing / flashing out of the cup, like its finding a better path to arc over. i did contact esab a long time ago but never really got a good answer. trying to weld with it doing this was impossible, so i switched tung type, etc.
Reply:SO the saga continues. I went and got a Diversion 180 and a new bottle of gas.3/32 Cerated tungston with 1/4 stick out. I spent the time to prep my surface 1/8 Alum using three different methods, first area I used a stainless wire brush , second area I used acetone wipe on wipe off, third I used an acid that my LWS sold me for prepping aluminum. I am no longer blowing through the aluminum but I cannot get any kind of a clean bead going. I get black rough globs at best. I am frustrated because I have done some decent Aluminum welds in the past. What else could I be doing wrong?Esab  Mig 200i Caddy Esab Tig 2200i ac/dc water cooled Miller Diversion 180Lincoln HD 110v weldpack
Reply:Like zipzit said - pictures tell a lot and save time.Most basic question #1 - Are you waiting until you see a nice shiny puddle before you try to add rod?question #2 - are you adding rod to the puddle and not letting the arc melt it?  If the arc melts it, you will not get a bead.Dave J.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Originally Posted by HundhausSO the saga continues. I went and got a Diversion 180 and a new bottle of gas.3/32 Cerated tungston with 1/4 stick out. I spent the time to prep my surface 1/8 Alum using three different methods, first area I used a stainless wire brush , second area I used acetone wipe on wipe off, third I used an acid that my LWS sold me for prepping aluminum. I am no longer blowing through the aluminum but I cannot get any kind of a clean bead going. I get black rough globs at best. I am frustrated because I have done some decent Aluminum welds in the past. What else could I be doing wrong?
Reply:Here is my mess[IMG][/IMG]These next two from large to small are 140,120,100,80 amps . Esab  Mig 200i Caddy Esab Tig 2200i ac/dc water cooled Miller Diversion 180Lincoln HD 110v weldpack
Reply:is the AC bal correct? on my 161 at 50/50 bal i get nice cleaning all the way around. in these pic looks like its all to one side? do you have gas lens?did you prep the metal before welding it? it has shiny appearance, looks like some type of coating??Last edited by welding_kid; 06-11-2013 at 12:00 PM.
Reply:Wiped with acetone. This was done with a Miller 180 Diversion so no AC balance to play with. Will find a few more pics with stainless wire brush prep and acetone wipe. Using an acid was I am getting the same results Esab  Mig 200i Caddy Esab Tig 2200i ac/dc water cooled Miller Diversion 180Lincoln HD 110v weldpack
Reply:Esab  Mig 200i Caddy Esab Tig 2200i ac/dc water cooled Miller Diversion 180Lincoln HD 110v weldpack
Reply:looks like contamination. 100% argon? what flow rate?are you letting the tungsten hit the metal?
Reply:Looks like bad gas or gas delivery issue. What size cup? Flow gas?The wrong combination can create a venturi effect dragging air into your gas stream. Do you have the collet body seated firmly? Is the collet faced in the right direction?If you could list all these conditions, it would help a lot.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:Originally Posted by welding_kidlooks like contamination. 100% argon? what flow rate?are you letting the tungsten hit the metal?
Reply:what type of tungsten?
Reply:2% CeratedEsab  Mig 200i Caddy Esab Tig 2200i ac/dc water cooled Miller Diversion 180Lincoln HD 110v weldpack
Reply:Originally Posted by shovelonLooks like bad gas or gas delivery issue. What size cup? Flow gas?The wrong combination can create a venturi effect dragging air into your gas stream. Do you have the collet body seated firmly? Is the collet faced in the right direction?If you could list all these conditions, it would help a lot.
Reply:Originally Posted by Hundhaus#7 cup using as set up out of the box. 20 cfh
Reply:The 2200i is an inverter machine and afaik so its the diversion.  Ditch the pure or ceriated tungsten for some zirconated.
Reply:Originally Posted by greenbuggyThe 2200i is an inverter machine and afaik so its the diversion.  Ditch the pure or ceriated tungsten for some zirconated.
Reply:It's gas.  NOT the tungsten.  There is no tungsten that would make that happen.Post a pic of your torch in exploded view if you can.If you looked at my thread youd see the same problem.  Grab another tank of gas somehow and try the machine.Change to a new wire brush also.  If you swirl with no filler, even on a clean but Unbrushed piece of aluminum, you should be all silver and white with zero black.I have my second bottle of bad gas from the same supplier now.  The guys literally a mile from me.  I have to drive 20 to the guy with the good stuff.  Argon mixes great from him, he just can't seem to get pure right.Last edited by Drf255; 06-12-2013 at 05:47 AM.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 MagnumI've got some practice beads that look exactly like yours.  I discovered that I wasn't waiting long enough for the puddle to form.  The puddle will look super shiny, like molten silver.  Try this, just light up on one spot and gently move the torch in a small (smaller than a dime) circle with no filler rod.  Then stop, hold for post flow, then pull the torch away.  You should have a clean, shiny circle of aluminum.You have to be closer to aluminum with the tungsten than with steel and aluminum takes more amps.
Reply:Gentleman we have found the root cause of all my problems( at least those related to Tig welding lol). As many of you had suggested....we have TWO bottles of bad gas!!!The field Rep from Air Gas came to my house with a bottle. He tried the old tanks and said right off the bat that both tanks were bad. We hooked up his little tank and we had success on the first attempts!!Now I can sleep. It is hard when you know you want something to work and something out of your control gets in the way. I have almost had my pride broken by a poor product. I have been so frustrated over this whole problem for weeks. Now I feel relief! Thank you all for your help. I am so happy to have a community that offers so much support. Will post up some pics tonight of my progress.Esab  Mig 200i Caddy Esab Tig 2200i ac/dc water cooled Miller Diversion 180Lincoln HD 110v weldpack
Reply:two bottles of bad gas?? is that shop cutting argon down to save a few $$ ??dont most places have argon brought in?
Reply:Congrats.You bought another TIG welder just cause the problem persisted.I know where your head was at, I was nearly there with mine.Good Luck.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Awesome. Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:Originally Posted by Drf255Congrats.You bought another TIG welder just cause the problem persisted.I know where your head was at, I was nearly there with mine.Good Luck.
Reply:Originally Posted by HundhausWiped with acetone. This was done with a Miller 180 Diversion so no AC balance to play with. Will find a few more pics with stainless wire brush prep and acetone wipe. Using an acid was I am getting the same results
Reply:Originally Posted by con_fuse9FYI the diversion is 72% EN balance and running at 120Hz.  Output is what Miller calls "Advanced Square Wave" which is a square wave with squared off corners vs. what Miller calls soft square wave.
Reply:Originally Posted by con_fuse9FYI the diversion is 72% EN balance and running at 120Hz.  Output is what Miller calls "Advanced Square Wave" which is a square wave with squared off corners vs. what Miller calls soft square wave.
Reply:Just a few pics from this morning. 3/16 3003 tigged dirty , as pulled from the scrap barrel this morning just to see for myself what the cleaning action looks like. Not great but far from what I was dealing with a few days ago.Esab  Mig 200i Caddy Esab Tig 2200i ac/dc water cooled Miller Diversion 180Lincoln HD 110v weldpack
Reply:Looks like you are about ready for your dog crates - if that's what you are making again.Be sure to post some pics Dave J.Last edited by MinnesotaDave; 06-13-2013 at 09:48 PM.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Originally Posted by MinnesotaDaveLooks like you are about ready for your dog crates - if that's what you are making again.Be sure to post some pics Dave J.
Reply:3003 vs 6061?Does this help? http://www.metalsdepot.com/products/...tml?page=sheetDave J.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Originally Posted by MinnesotaDave3003 vs 6061?Does this help? http://www.metalsdepot.com/products/...tml?page=sheetDave J.
Reply:Just a heads up as to what I like to use with my Esab 2200i, I've found that the 2% lanthanated (blue) or the Tri mix (white) seem to run the best with the machine so far.
Reply:I dont wanna create separate topic, since its not big question. Just received brand new 2200i AC/DC T34 for 1750$ (save 2k$ instead choosing the blue box...) and for me was strange when I turn on the fans making quite loud noise. Machines that I had worked before didnt make such a loud noise or they turn on full speed then machine is hot, but then I find one review video where things seams like was the same, so just wanna ask other 2200i owners or its the same in your case?He turn on machine on 2:00
Reply:Yes, the fan runs full time.... Just like my water cooler..Esab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i