Farting Around With Some Scrap Aluminum, Tig & Stick

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Day off work, raining out, whats a guy to do besides screwing around in the garage?  I had some scrap pieces of aluminum that would never amount to much so I decided to play around with the tig machine.    I haven't spent much time welding aluminum, and just recently started to become a little more comfortable with it.  It can still be frustrating at times for me, but at least I can actually make it happen at this point.   This was all done with about 150 amps on the dial (foot pedal), a 17 torch with 3/32" 2% lanthanated, and 3/32" 4043 filler.  The stock is mostly .125" unknown-alloy aluminum.    I usually have trouble initiating a clean puddle without melting over the edges when I first start to weld, but I've also found that getting things warm with a propane torch helps immensely.  You can see in the third pic I tried some thicker pieces, which I didn't think would work out with my little 175 amp machine.   After getting it hot with the torch and cranking the machine to max I was surprised to find I could actually get a puddle flowing between the two pieces, although the small overall mass of the workpiece helped I'm sure.  Next up I figured I'd burn some of those 1/8" 4043 stick rods I bought a while back.   The last time I tried these I nearly threw the tube of rods across the street they pissed me off so much.    My first pass was at about 115 amps and surprisingly it worked!  It sure was ugly but I would call it a succcess considering my last attempt with these.  I then tried a pass at about 100 amps (no pics), and it actually seemed to do a better job than the hotter pass.  These things may be messy and difficult to use, but if I had to fix something ugly and possibly too thick to tig, I wouldn't hesitate to use these rods!
Reply:I can say I have never used rod on Aluminum nor stainless. That was interesting, thanks for posting.Regards,RobGreat Basin WeldingInstagramBlue weldersRed weldersMy luscious Table DIY TIG Torch cooler
Reply:I have used aluminum stick for years. Not and never will be pretty like Tig. But they weld good with practice. And you hit it right on the head with the pre heat. I heat anything over 1/16. It takes practice because the puddle is different and harder to see and read than steel. And you have already seen, the rods burn fast. Proud of you!        ChuckTo ride, shoot straight, and speak the truth. This was the ancient law of youth. Old times are past, old days are done, but the law runs true oh little son.Winpower 180 DCSA-200 redfaceXMT-304
Reply:Yeah aluminum stick can be tough - one thing is that slag will rust your steel table if you don't clean it up (I don't know why).  I did not one day and had to fire up the wire wheel to get it clean.Tig looks like it's coming along On your third hand, remember to put something on the end or it will leave black arc marks on your aluminum.I tigged some copper house wire on the end of mine - that fixed it   Welds almost like a steel filler rod.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:Thanks for the comments, guys!  I've learned a lot here from you grizzled veterans... Originally Posted by MinnesotaDaveOn your third hand, remember to put something on the end or it will leave black arc marks on your aluminum.I tigged some copper house wire on the end of mine - that fixed it   Welds almost like a steel filler rod.
Reply:Here's one I forgot to post.   Beside the lap ran with the stick rod, I did one with tig, 150 amps.  Cut 'er in half and smoothed it off with a lathe file.  Granted I'm no expert, but I thought it was a nice tig pass and was shocked to see how much better penetration I had with the stick electrode!  I know its a little difficult to see, but tipping your monitor may help...