Can't fuse aluminum - tig

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Ok, what I'm seeing is that I'm having a really hard time getting aluminum to fuse.  I can join the aluminum by making a puddle OVER the root, but I don't seem to be getting any penetration INTO the root.This is 1/16" x 3/4" round tube welded (kindof) onto 1/8" x 3/4" flat bar.  As you can see, there doesn't seem to be any penetration to the root.I was running around 20cfh argon, 55amps ac, no pulse.  Synchrowave 180.  Decent amount of stickout with a gas lens.  1/16" ceriated tungstens, 90degree point, flat tip.I seem to be able to blow right through the 1/16" tube, and still not get them to join.  I can only seem to lay a bead on top of the two pieces.  Thankfully, these pieces are only to hang some curtains, but this is practice for a more serious piece that can't fail.Lincoln HD3200 MIGMiller Synchrowave 180 TIG
Reply:55 amps?Try 155 amps and burn it in. Move up to 3/32 tungsten and #7 cup if you are going to use 20cfh argon.Otherwise AC welding loses a lot of heat in the arc gap. So you have to murder the puddle if you want desired penetration. Technique takes care of the cosmetics.Of course adding helium helps.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:What kind of aluminum? Some of them are not very weldable.the 2000 and 7000 series  of aluminum are  not very weldable.Hey~!! It's a hobby. It's not supposed to make sense~!!
Reply:Yep, listen to shovelon - I recently did some 1/16 to 1/8 and 1/16 to 1/4 - lots of amps, puddle on the thick side and run it over to the thin - add rod.  I was over 200 amps on the 1/4" and I was adding rod as the 1/16" would start to keyhole, the puddle would wick up and fill the keyhole and I kept moving. I used 3/32 red tungsten, #7 gas lens an on old Airco.  My results were not picture perfect, but it was my first try with thick-to-thin.Worked for me, maybe someone here could explain it better.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:155?  Wow.  I was blowing through at 75.It's some 6xxx series, nothing exotic, just from the hardware section at Home Depot.Well, this gives me some direction.  Thanks!Sounds like1.  More amps.2.  Less argon.3.  Larger tungsten.I'm going to have to move way faster to avoid blowing holes.Lincoln HD3200 MIGMiller Synchrowave 180 TIG
Reply:You could also try to sharpen the tungsten to a very narrow, longer taper.  Perhaps this way the arc won't want to jump from the sides of the tungsten onto the "sides" of the aluminum and focus it more in the root/joint. 1st on WeldingWeb to have a scrolling sig! HTP Invertig 400HTP Invertig 221HTP ProPulse 300HTP ProPulse 200 x2HTP ProPulse 220MTSHTP Inverarc 200TLP HTP Microcut 875SC
Reply:Why are you fusing it?   Use some filler........After looking at the picture it almost looks like anodized or some type of coating for a cosmetic appearance. The one tack or melted portion looks nasty dirty?Last edited by B_C; 06-01-2013 at 02:40 PM.  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Originally Posted by B_CWhy are you fusing it?   Use some filler........After looking at the picture it almost looks like anodized or some type of coating for a cosmetic appearance. The one tack or melted portion looks nasty dirty?
Reply:Originally Posted by clearchris155?  Wow.  I was blowing through at 75.It's some 6xxx series, nothing exotic, just from the hardware section at Home Depot.Well, this gives me some direction.  Thanks!Sounds like1.  More amps.2.  Less argon.3.  Larger tungsten.I'm going to have to move way faster to avoid blowing holes.
Reply:Originally Posted by MinnesotaDaveYou don't really move faster, just very carefully moving and adding rod.If your amps are too low, instead of making a puddle, you end up just heating and heating until the puddle blows out.  Your goal is to puddle in a few seconds - like 3 or so.  Then you can back off the pedal as needed.Dave J.
Reply:D_C and weldermike:  heh, if you think it looks dirty say so.  I have no pride in this, all I want is a good weld and if it takes people saying I suck, I'm fine with that.That said, I think that's more the closeup grainy cropping than anything.  Here's the full picture that was too big for me to upload to weldingweb.  I also think part of my problem is I don't hold the tungsten close enough.  I have been working on that, but there's a fine line between holding it close enough, and sticking the tungsten with the filler rod.I'll report back after I make another attempt tomorrow.Lincoln HD3200 MIGMiller Synchrowave 180 TIG
Reply:That didn't work so well.This should be clickable.And I have had some problem with the welds being "dirty" after welding (left piece) but they didn't start like that.  Not sure what I'm doing, but sometimes when I light up the torch all I do is oxidize the metal.  Doesn't happen too often thankfully.Lincoln HD3200 MIGMiller Synchrowave 180 TIG
Reply:What is your actual arc length? With a 90° vertex I'm willing to bet the arc is jumping too far away from the joint, one, because its an inside corner joint to begin with, and two, there might not be enough taper on the tungsten, making the arc jump from the closest distance to the work piece.  What do you have the AC freq. set to?  I'd try a vertex angle ofabout 30° or less if possible.  This would keep the tungsten "sides" further away from the joint, perhaps facilitating having the arc jump from only the tip.Last edited by Oscar; 06-01-2013 at 06:45 PM. 1st on WeldingWeb to have a scrolling sig! HTP Invertig 400HTP Invertig 221HTP ProPulse 300HTP ProPulse 200 x2HTP ProPulse 220MTSHTP Inverarc 200TLP HTP Microcut 875SC
Reply:I see the pics, but now I'm wondering what I'm seeing, your original post said you were welding 1/16" tubing to 1/8" plate?The pics look different than that?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:Oscar:  I'll try that.  Thanks.MinnesotaDave: 1/16" x 3/4" OD tubing cut to 1" length.  The 1/8" x 3/4" bar is cut to 3" length and drilled both ends.  One of each set, I notch the tubing on top, spot weld the sides and open it up to a "U" shape.  I thought that would add unneeded complexity to explain, and I was seeing the same issues on the plain tubing and bar anyway.  For an example of what I'm trying to make here, do a google search on "inside mount curtain" or check this link:http://www.madeofmetalcurtainrods.co...t_bracket.htmlI'm making almost 20 sets of these.  Mostly, I'm doing it because I need some practice, but it also helps that I'm impatient and didn't want to wait for them to be shipped.  Plus, saving 400$ helps too.  I would have done them with mild, but for 20 sets of these, I wanted something I could machine easily and quickly.  So far I'm into this for 30$ in aluminum, one hour cutting/drilling and 3 hours trying to weld aluminum.  It will probably be a wash by the end, but I'll have picked up some welding skill in the process.Edit: Heh, looking at the link, their welds aren't entirely cosmetic either.Lincoln HD3200 MIGMiller Synchrowave 180 TIG
Reply:Just optical illusion - thought your 1/16 tubing looked way thicker.  My mistake. 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:Maybe this will help.  In this video Jody welds some thick to thin aluminum.Exellent close up arc shots.[ame]http://www.youtube.com/watch?v=nObJE9LScYE[/ame]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:Pretty much straight forward weld......small stuff can be challenging, just take your time and get comfortable........  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock