Anodized aluminum

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Hey guys, new here to welding web. Having a problem with a back up machine, lincoln p/t 275 and anodized coating, looking for some advice as the guys over at lincoln said they have never seen this before?I I normaly work with a dynasty 300 but its out for service and have to finish a project, so in a real bind. It looks like that the first tack on material is placing thousands of cracks in the anodized coating up to six inches around the weld. Never had this before, but never used this machine for this application either. I've tried a differant bottle (100% argon), new tungsten 2% ceriated as first choice and pure as second. No major  differance in surrounding areas, just a differance in the weld quality. Any ideas??Thanks, Mike Attached Images
Reply:So you are welding over the finish?Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:Yes, cut and weld. Finished product. Never had this happen with my inverter machine?
Reply:ps,Need more info.Base metal (6061?)Are you "bump welding"?Amps.Balance setting.Doesn't look like you were bump welding that part.  Were you using a pedal or an on/off switch?That's definitely unusual.  Looks like the problem occured only on the vertical piece and not on the horizontal piece.For bump welding that on a Dynasty 300, I'd be at about 80-90HZ, 195-200A, with balance set to 80-85.With the Sync I'd be welding it a little slower at 190 or so A, with balance set to 85.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Thanks for your response. Base metal, 6061 .125 wall. Never used this machine for this type of welding, but you have to do what you have to do. Amps at 180, cleaning at 3 o-clock (75%) en. On/off finger control, no ramp either way, no controll over hz, 60 im guessing? Both sides were effected. Crazy. Started this job with 300 dx and it went on the fritz, so its out for service. It's all the same material I started with and did not have any probs till I switched to p/t 275. Any thoughts.....
Reply:It's not a transformer vs inverter thing.  Anodized aluminum has been successfully bump welded when we were still using the Miller 330 A/BP's.Having a little trouble figuring out what's going on here.  Is the welder left handed?  Looks like a lot of inconsistency, especially "turning the corner".  Not real happy with that "gopher hole" either.It looks (graininess) like you're using 4043.  Have you tried 5356?Also a little miffed about the lack of an apparent etch zone adjacent to the bead.What size cup and are you using a gas lens?  What is your argon flow and have you checked to insure that you're getting good coverage?  Any problem with the tungsten turning blue?How far is your work lead from the weld?  The work lead IS attached to the work isn't it, not just sitting on a grounded table.Does the sample show any arc burns other than in the area of the weld?Sure looks like possibly you got some stray current that's working on the anodizing where it's not supposed to.  This almost always goes back to grounding/work lead placement.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Sundown, I'm baffeled aswell. I understand the inverter thing as I worked with a s/w 355 and anodized for a while back in the day. The sample shown, Not very good, was a quick one for lincoln tech Dan. I am a left holder, right feeder. Ground is always on work and not the table and I dont belive it's a gas thing, cup is 7 and tungsten is 1/8. Ark is for the most part stable, and tungsten is frosty but clean. I feel there is some sort of current feeding through here. It happens almost instanly, by the time you get one corner tacked, so it's not an overheating this as suggested by everyone. It welds mill finish great and crisp and dc is crisp aswell??. I'm ready to push it out in traffic and say far well   This has got to be the strangest thing I've seen and I'm going to continue trying to get a Lincoln rep down here to view first hand. I have tried 1/4 plate, polished pipe, and brushed pipe is the worst. It turns completely frosty white 4 inches above notched joint. Please??????????
Reply:pslwelder,Man, I can feel your pain.Sounds like you're having this problem with other parts/material also.  Everything I've asked about, you've been right on the money about what you've tried.About the only thing left is a problem with the machine (welder) that I can't figure out.  I've never run into this type issue, so I'm not much help there.  It would sure be interesting to learn what the Lincoln reps say.If it was my machine, it would be at the service shop (ArcWelders in Ashland, VA) and we'd be looking at the output on a scope.I've welded with the Lincoln machines but I've never owned one so I can't compare their tech support to Miller's, but I will say that Miller has always been great.  Since you own a Dynasty (in the shop), I'd call Miller and ask them if they've ever had these issues.Do you possibly have a buddy in the area that could try welding up your material on another machine?  That would further rule out a material/anodizing issue.  I weld both the brushed and bright finish aluminum and see very little difference between the two as far as how they weld.Please let us know what you find.PS.  May help for you to post up where you're located.  May be someone local who'll chime in and offer to try your samples.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Sundown,    Lincoln is sending a rep up on thursday morning. He's got a V 205 to play with, still no 300dx but would make nice back up.. Should be interesting, Maybe he'll go home with a 275.... Will let you know how things work out. Thanks for your support!!P.S Located in Port Saint Lucie Fl
Reply:What is bump welding?Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:Gamble,   It is a technique used to weld anodized material using a forceful start and a torch mounted switch. Difficult to explain in words, similar to a manual pulse, on-off-on with no ramp up or down. It aids in blasting off the coating for a cleaner puddle. Im sure sundown's 20 Plus years on me, could explain it a bit better.
Reply:Easy off oven cleaner in the yellow can removes anodizing and leave a very nice raw aluminum finish.Welding/Fab Pics: www.UtahWeld.com
Reply:MikeGyver,     Thanks for the information, many of times wished it could be removed prior to welding myself. However,In this application, it cannot.
Reply:psl,I could, but I won't.Process has been described here several times.  Even linked to an article in Metalforming magazine that described how Pipewelders (in conjunction with Miller) developed the process.A simple search can do wonders for the inquisitive.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Sundown, Fair enough
Reply:Well juries in and the verdict......I don't know, I've never seen anything like this before. Lincoln rep was in today, very nice man and inelegant to talk to, however no help to me. I showed him some samples first hand and he had no clue, never seen anything like it. We both agree somethings wrong and theres some sort of stray current attacking the anodized coating (god only knows what its doing to my body). With that said, he took a few samples to fed ex up to an engineer in Cleavland to get his opinion on it. In the mean time, he overnight me a brand new 25' w/c torch at no charge to me to see if this would help. If you cant fix it, bribery works all the time! As far as the v205 to demo, it never showed, it was out on another site??? So tomorrow I will install new torch when I get home, doubt it will help but you never know and take it from there. Looks like it's going to be a hurry up and wait thing. Will post more as I learn myself.
Reply:psl,Have you tried the machine on a "different batch" of anodized aluminum?I've got plenty of anodized aluminum in the shop, but if you want to send me a couple samples from that batch, I'll be happy to run them on both the Sync and Dynasty.Just PM me and I'll shoot you an address.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Sundown, Thanks, that's a pretty cool thing for you to do, but not necessary. I started the project with my 300dx  and no problems at all. It was only after switching the machines I noticed it. I've tried different material from e-tec and eastern, don't believe it's a material problem. I also gave Lou some material to weld on his  v205 tonight, see what he says then. Thanks for your help.
Reply:psl,Know we're "grabbing at straws", but sometimes one of those straws might just be in a mai tai.Does that Lincoln have an adjustment for the Hi Freq intensity like found on the older Syncs?  If it does, you may want to try turning it down a bit.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Pslwelder; my thought on this is- the transformer welder has no adjustment to the frequency. It's forcing you to use a slightly slower frequency than you would usually use on an inverter rig. It's leaving you with a wider footprint than you usually get is my guess.A suggestion; try to go with bigger dabs, or a bigger filler rod. On the Idealarc 300 I sometimes use, I literally throw 1/8" filler in like it was going down a hole. The puddles are big, so I need to use a wall of filler. For bigger pipe welds, I actually hit the 5/32 filler. Hopefully, the issue is not one that you can't overcome with that machine. Good luck! Paul.And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:Sorry, no adjustable H/F on this one. I am running out of options my self, but not the end of the world as it's only a back up machine and the blue beast will return.Thanks for the info on filler.  The picture I posted was not the greatest choice, but I was pissed and in a hurry to get a sample pic over to tec-support. I understand this is going to leave wider, less focused bead compared to my 300. That's no the prob, the prob is the anodizing crazing a great distance away from the bead. Transformer machines can weld anodized well,yes they are not as forgiving as the newer inverters. Just requires a bit more talent and patience, I did back 4-5 years ago with a Lincoln s/w 355 and never seen these issues b4. Gunna wait for the new torch Monday, who knows, might work great!! I posted another pic that was done with more scrap last night. As you can see the machine welds pretty good but look close and you'll see the damage to the pad. It crazes polished and frosts brushed. Who Knows... Attached Images