seek'n alum TIG perfection

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I ran three beads at three separate AC wave balance settings in an effort to find one that could give results close to those beautiful crisp beads that I know I'm capable of.  Iv'e TIG welded a lot of alum of different thickness and alloys but the results are usually similar to the attached example (note the little pimples in the puddles). Would a different filler rod or one matched to a known alloy make a difference? Suggestions?Also, although it may be due to the rough surface...does the etching around the beads look excessive in your opinion? Material: 1/4" unknown alum alloy cleaned w/ grinder sanding wheel and brushed w/stainless brush used only for aluminum cleaning.Filler rod: alum 4043 3/32" suggested for various or unknown alloys.Gas: Argon at a flow rate of 20cfh  Electrode: 3/32 pure tungsten w/ freshly balled tip, stick out just shy of 1/8"Cup: #7Machine: water cooled Lincoln 275 sq wave w/ foot amptrol.AC wave balance setting (0-10) set at:.     TOP BEAD #8 penetrating (higher negative current than positive).   .     MIDDLE BEAD Auto balance  .     BOTTOM BEAD #3 = balanced positive / negative current Attached ImagesLast edited by badknot; 11-27-2011 at 10:01 PM."Steel is weak. What is steel compared to the hand that wields it?"- James Earl Jonesmiller 225 w/ 3035spoolmate, Lincoln sq wv 275 w/radiator, hypertherm 600 plasma cutter, other stuff
Reply:1/4" is pretty heavy. How many amps are you running? I've noticed the students often get that "pimply" look when they run too slow at too low an amp setting and over heat the material..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:I'm using a foot amptrol and didn't note the logged peak current output. Generally I figure I just use as much as i think i need, lol, I know the top bead could have used a little more heat/current. The beads went fast enough..or, so i think and seem to be my typical results on various thickness. Also is the etching around the beads excessive in ur opinion?Last edited by badknot; 11-27-2011 at 10:38 PM."Steel is weak. What is steel compared to the hand that wields it?"- James Earl Jonesmiller 225 w/ 3035spoolmate, Lincoln sq wv 275 w/radiator, hypertherm 600 plasma cutter, other stuff
Reply:Originally Posted by badknotI ran three beads at three separate AC wave balance settings in an effort to find one that could give results close to those beautiful crisp beads that I know I'm capable of.  Iv'e TIG welded a lot of alum of different thickness and alloys but the results are usually similar to the attached example (note the little pimples in the puddles). Would a different filler rod or one matched to a known alloy make a difference? Suggestions?Also, although it may be due to the rough surface...does the etching around the beads look excessive in your opinion? Material: 1/4" unknown alum alloy cleaned w/ grinder sanding wheel and brushed w/stainless brush used only for aluminum cleaning.Filler rod: alum 4043 3/32" suggested for various or unknown alloys.Gas: Argon at a flow rate of 20cfh  Electrode: 3/32 pure tungsten w/ freshly balled tip, stick out just shy of 1/8"Cup: #7Machine: water cooled Lincoln 275 sq wave w/ foot amptrol.AC wave balance setting (0-10) set at:.     TOP BEAD #8 penetrating (higher negative current than positive).   .     MIDDLE BEAD Auto balance  .     BOTTOM BEAD #3 = balanced positive / negative current
Reply:-going more unbalanced-towards 'penetration' reduces the HF cleaning effectTry going all the way-unbalanced, towards 'penetration' on stuff that's cleandave it is not the HF that causes the etching, it is the electrode positive part of the A/C current.Setting the machine for more penetration (more electrode negative) makes a smaller etched area around the weld.Also don't know why you said 5356 filler would look better.I agree with DSW about too low amps/ too slow travel speed. The op said he set the machine to more pen. on the first weld but the etched area seems about the same size as the other welds have, also makes it seem like slow speed/low amps. badknot try setting the amps higher and run the bead at a faster travel speed with balanced A/C. If you still want a smaller etched area set for more pen.
Reply:HF helps maintain a focused arc which would result in a narrower etchingHTP Invertig 201Lincoln Idealarc SP250Miller 180 AC StickBy farmall:They should have held the seagull closer to the work, squeezing evenly for best deposition.
Reply:"Iv'e TIG welded a lot of alum of different thickness and alloys but the results are usually similar to the attached example "i find that statement a little hard to swallow.  were you getting paid?
Reply:Originally Posted by DSW1/4" is pretty heavy. How many amps are you running? I've noticed the students often get that "pimply" look when they run too slow at too low an amp setting and over heat the material.
Reply:Originally Posted by fdcmiami"Iv'e TIG welded a lot of alum of different thickness and alloys but the results are usually similar to the attached example "i find that statement a little hard to swallow.  were you getting paid?
Reply:just a side note. test piece is left over channel stock used as decking on my boat lift project last month. i got it from my local scrap yard @ .40 cents a pound and It was heavily oxidized.  Even though I cleaned the weld areas It may not have been sufficient enough and may have contributed to my less than stellar  welds.  While most of my beginning welds looked similar to the example they started looking better by the time i found my rhythm but still not what I had envisioned which is why I started farting around with my technique on this scrap piece yesterday.  possible i may have just embedded some of that oxidation when I sanded it?"Steel is weak. What is steel compared to the hand that wields it?"- James Earl Jonesmiller 225 w/ 3035spoolmate, Lincoln sq wv 275 w/radiator, hypertherm 600 plasma cutter, other stuff
Reply:Next time try cleaning with acetone and then scratch with a SS brush untill you feel the brush getting harder to drag across the aluminium. Sanding is not recommended but I don"t know if it would cause any problems.
Reply:"HF helps maintain a focused arc which would result in a narrower etching "           fordman HF is used to start and maintain the arc in a/c not focus it.
Reply:sanding using an aluminumoxide type sand paper WILL leave what you are trying to remove with the brush an cleanerwhy most just a SS brush an cleaneridealarc 250/250 ac-dc tigidealarc 250/250 ac-dc tig #2 used for sticklincoln sp100hh125dual arbor grinder polisher30 yrs of hand tools52 pitch blocks 6p-26prake gauge -pitch gaugeG&D prop repair 918-207-6938Hulbert,okla 74441
Reply:It would take a lot elbow grease to clean this w/only a stainlss brush and acetone but I get ur point. an after thought; probably should have switched to a fresh sanding pad after removing oxidation before finishing w/ stainlss brush and acetone. Attached ImagesLast edited by badknot; 11-28-2011 at 03:02 PM."Steel is weak. What is steel compared to the hand that wields it?"- James Earl Jonesmiller 225 w/ 3035spoolmate, Lincoln sq wv 275 w/radiator, hypertherm 600 plasma cutter, other stuff
Reply:Try the acetone and ss brush without sanding to see if it helps. I think the thing that will help you most is turning the amps up.
Reply:Originally Posted by SquirmyPug"HF helps maintain a focused arc which would result in a narrower etching "           fordman HF is used to start and maintain the arc in a/c not focus it.
Reply:http://www.yellowbullet.com/forum/sh...d.php?t=127750Possibly perfection in alum weldingIf you read thru this thread they eventually get to some help on how those welds are produced.
Reply:Originally Posted by badknotAC wave balance setting (0-10) set at:.     TOP BEAD #8 penetrating (higher negative current than positive).   .     MIDDLE BEAD Auto balance  .     BOTTOM BEAD #3 = balanced positive / negative current
Reply:Mario...  this guy is SICK!!!!1  For those who think they have a handle on TIG welding aluminum you need to look at all 61 pages of this (to date).   http://www.yellowbullet.com/forum/sh...d.php?t=127750
Reply:I spent the last hour looking at pictures of Mario's manifolds......amazing welding, casting. Everyone interested in welding should visit that site just to look at the pictures and drool.http://www.yellowbullet.com/forum/sh...d.php?t=127750
Reply:Badknot, you are doing alright. Just keep practicing, and you will get the little things sorted out. I agree with Dave Powelson as for some settings, material and tweaks.I will sand material like that first, then take a brush to it for a second after I have loosened up a lot of the oxidized top layer. Looking ok, and a good starting point.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:Originally Posted by Ken SmithI spent the last hour looking at pictures of Mario's manifolds......amazing welding, casting. Everyone interested in welding should visit that site just to look at the pictures and drool.http://www.yellowbullet.com/forum/sh...d.php?t=127750
Reply:Sorry, I got the name wrong......I meant Marcella. Also, the link did not transfer correctly. I thought the link had imbedded in the post, like in Bentwing's post, but it says 404 error. Hmmmm.Marcella's work is something to aspire to.
Reply:Is it possible to increase the AC frequency on my 2001 lincoln 275 SWT?  this model doesn't have a AC frequency setting selector, it has internal contact points to control the frequency if I understand correctly. The manual lists the factory gap at 0.15 (.4mm) set for most applications and notes that the gap can be reduced if less high frequency is desired but does not mention anything about increasing the frequency. Will increasing the gap increase the frequency? Will it cause damage to the machine?Last edited by badknot; 12-04-2011 at 10:41 PM."Steel is weak. What is steel compared to the hand that wields it?"- James Earl Jonesmiller 225 w/ 3035spoolmate, Lincoln sq wv 275 w/radiator, hypertherm 600 plasma cutter, other stuff
Reply:badknot,Not possible on your transformer machine.The ability to adjust the AC frequency comes with the newer inverter based designs.With your squarewave transformer based machine, your AC frequency is set at 60HZ, which is the frequency the AC comes out of the wall.Adjusting the AC frequency on the inverters allows the welder to "tighten/focus the arc for a smaller bead profile and more penetration--higher frequencies".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.Originally Posted by Ken SmithI spent the last hour looking at pictures of Mario's manifolds......amazing welding, casting. Everyone interested in welding should visit that site just to look at the pictures and drool.http://www.yellowbullet.com/forum/sh...d.php?t=127750
Reply:more seat time, more beads. 5356 filler does seem to look nicer. I alternated between 100 tungsten and ceriated 2% tungsten and I've been using my gas lens. AC wave set all the way to penetrating.  As a hobby welder I'll probably loose any experience I may have attained by the time I need to do another aluminum project, which could be weeks or months. Attached Images"Steel is weak. What is steel compared to the hand that wields it?"- James Earl Jonesmiller 225 w/ 3035spoolmate, Lincoln sq wv 275 w/radiator, hypertherm 600 plasma cutter, other stuff
Reply:Originally Posted by VPTIs there mention of the thickness of the material he is using? It is much easier to lay nice aluminum welds on thicker materials.
Reply:Originally Posted by badknotmore seat time, more beads. 5356 filler does seem to look nicer. I alternated between 100 tungsten and ceriated 2% tungsten and I've been using my gas lens. AC wave set all the way to penetrating.  As a hobby welder I'll probably loose any experience I may have attained by the time I need to do another aluminum project, which could be weeks or months.