Tungsten, Filler size for big aluminum job??

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I have a job welding 300ft of 4" x 8" x 1/4"wall, 6061 aluminum tube. Historically I've used 3/32" tungsten and 3/32" filler for 1/4" aluminum. My question is would it benefit me to go with 5/32" tungsten and larger filer?  I've used 3032 filler and 5051 filler. I'm using my TB 251 with HF box . Any advice before I tool up at the WS? Thanks.Miller TrailBlazer 251Miller HF-250-1Miller MaxStar 150 STLHyperTherm PowerMax 380 plasmaLincoln PowerMig 180Millermatic 252Miller Diversion 180
Reply:3/32" tungsten sounds small for the amps generally needed for 1/4" alum. I'd be running at least 1/8" tungsten in lanthanated at 250 amps..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:How long will you have your arc going??? (aka duty cycle)???3/32 will start to deteriorate at long periods at high amperages....Btw,What amperage will you be welding at???Just a couple welders, big hammers, grinders, and torches.Work will free you.Men in dirty jeans built this country, while men in clean suits have destroyed it. Trump/Carson 2016-2024
Reply:300'......I'd be using my spoolgun!Miller Dynasty 200DXMiller 252 Miller 250xMiller Syncrowave 250Miller AEAD200 LegendMiller 375 Xtreme plasmaLincoln WeldPak 100Victor O/A
Reply:I'll be welding 4" x 8" tube, 45* miters and 4" x 8" tube "T" joints and but splice. The TB 251 is an Ac generator machine so I will be using 100% theorated tungsten, green,... Not an inverter machine. I'll be running over 200amps. Not worried about duty cycle just want Maximum tungsten life and quickest filler. Thanks.Miller TrailBlazer 251Miller HF-250-1Miller MaxStar 150 STLHyperTherm PowerMax 380 plasmaLincoln PowerMig 180Millermatic 252Miller Diversion 180
Reply:Originally Posted by DSW3/32" tungsten sounds small for the amps generally needed for 1/4" alum. I'd be running at least 1/8" tungsten in lanthanated at 250 amps.
Reply:Green is pure tungsten. Thoriated is red.You don't need to use green just because you have an Ac machine like that. Rare earth tungstens like lanthanated will ball less and slower than green ( pure) at similar amps. At high amps green won't hold up anywhere near as well as Lanthanated or ceriated will. In fact while those will still ball, you can "point" the tungsten and get a smaller ball that will hold up longer and give you more arc control, even with a basic AC machine like the TB. You "loose" some of the "benifits" of rare earth tungstens with a balanced AC machine, but the amp advantage stays the same as shown in the chart.From the chart I posted off Millers site, note that 1/8" pure is only rated to 180 amps on a balanced AC machine like you have. 1/8" Ceriated or lanthanated starts at 160 amps and goes to almost 250 with the same type machine. The higher amp rating means it will ball less and hold up better.You may find that you can run a smaller ball with say 1.5 or 2% lanthanated and get more arc control even with the machine you have. The smaller ball gives you a tighter arc and a bit more control over your arc.Filler wise, bigger filler means more deposited per dip compared with smaller filler. 3/32" would work, but since it's all on 1/4" material, you could go to 1/8" filler and the bigger filler would help chill the puddle some if that was the result you were looking for. I think Zap runs 1/16" filler for everything including big alum, so there's no reason you couldn't either. You just have to jam in more filler per inch of weld to get the same amount of reinforcement.Last edited by DSW; 04-07-2014 at 02:25 AM..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:DSW, thanks for the info.Miller TrailBlazer 251Miller HF-250-1Miller MaxStar 150 STLHyperTherm PowerMax 380 plasmaLincoln PowerMig 180Millermatic 252Miller Diversion 180
Reply:Hey Guys,HELP!  I went with the 100% tung, the guy at Ws said the lanthanated. would not work with my AC generator machine. Maybe my fault..Anyway. I started the welding stage of the project today. My TB with HF box, 1/8" 100% tung., 1/8" 4041 filler. With the TB at max amps. I'm way under needed heat. Takes way to long to do a tee joint...material is 6061 4" x 8" x 1/4" tube....I need much more amps. I'm going to try and rent a bigger machine but the local rental companies usually Carry the 250's. I'm considering trying helium versus argon.  Advice?????Miller TrailBlazer 251Miller HF-250-1Miller MaxStar 150 STLHyperTherm PowerMax 380 plasmaLincoln PowerMig 180Millermatic 252Miller Diversion 180
Reply:Use a rose bud or weed burner to preheat the parts.
Reply:I would be using 1/16" filler and be pumping it in but what do I know.......zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Originally Posted by 4956Use a rose bud or weed burner to preheat the parts.
Reply:Originally Posted by zapsterI would be using 1/16" filler and be pumping it in but what do I know.......zap!
Reply:Any opinions on using helium versus argon....I've used helium in a shop environment when welding massive aluminum dies.Miller TrailBlazer 251Miller HF-250-1Miller MaxStar 150 STLHyperTherm PowerMax 380 plasmaLincoln PowerMig 180Millermatic 252Miller Diversion 180
Reply:Any opinions on helium versus Argon for greater heat?Miller TrailBlazer 251Miller HF-250-1Miller MaxStar 150 STLHyperTherm PowerMax 380 plasmaLincoln PowerMig 180Millermatic 252Miller Diversion 180
Reply:Any one run a wire feeder with spool gun for aluminum off a TB?? Historacially, I'm not a fan of aluminum mig. I've never acheived a satifiying bead using an aluminum squirt gun.Miller TrailBlazer 251Miller HF-250-1Miller MaxStar 150 STLHyperTherm PowerMax 380 plasmaLincoln PowerMig 180Millermatic 252Miller Diversion 180
Reply:Ditch the pure tungsten. E3 will work well for you and everyone has it. Point it and let it melt back gradually. 1/8th works well in most applications like yours.Yes, helium will help immensly in your situation, but 25% helium is maximum otherwise you risk arc rectivication on your tranny welder. You can buy 75ar/25he mix at your LWS. 4943 is great filler for your application. It flows fast and is not dependant on base metal dilution for strength like 4043. 3/32 dia. Would the size I would go with and is the most common.What is the max amps you can get from your machine?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:Great Day Guys!Thanks so much for the information. I picked up some 2% Ceriated, 1/8" tungsten this morning. The LWS did'nt have Lanthanated 1/8". I was able to dial the TB back to 175 and kicking a*s! Welding like butter! Thanks again! I guess I'm too old school and need to update my knowledge of current tech and tooling. Any new magic that will keep aluminum from heat drawing? HA.Miller TrailBlazer 251Miller HF-250-1Miller MaxStar 150 STLHyperTherm PowerMax 380 plasmaLincoln PowerMig 180Millermatic 252Miller Diversion 180
Reply:Originally Posted by shovelonDitch the pure tungsten. E3 will work well for you and everyone has it. Point it and let it melt back gradually. 1/8th works well in most applications like yours.Yes, helium will help immensly in your situation, but 25% helium is maximum otherwise you risk arc rectivication on your tranny welder. You can buy 75ar/25he mix at your LWS. 4943 is great filler for your application. It flows fast and is not dependant on base metal dilution for strength like 4043. 3/32 dia. Would the size I would go with and is the most common.What is the max amps you can get from your machine?
Reply:Originally Posted by waginThanks for the information. I had to look up arc rectification. Are you saying that using pure helium can cause my AC arc to convert to DC only? How does that work? I do not know what E3 tungsten is but I changed from 100% to 2% ceriated today and it allowed me to run hot welds at 175 amps. I had the TB maxed out with the 100% and very cold. I'm not sure what my Tb's max amp out put is. The TB is a 1999 year model. Also, I attempted to buy 4943 filler today at the LWS but they have never heard of it. Said it was a typo, meaning 4043. HA.
Reply:You can get a ten pack of the 2% lanthinated on ebay for about $30http://www.ebay.com/sch/i.html?_odkw...1%2F8&_sacat=0it's much better than than the ceriated you have. I'd also not use welding supply place who gave you that bad advice. When I started welding about 2 years ago , I also read that the 100% green tungsten was best for aluminum, let me tell you it sucks! Also read balling up the end of the tungsten was mandatory, also bad advice IMHO.
Reply:You know 1/4" aluminum is a good candidate for welding with DCEN.