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I just got my new Miller Syncrowave 200 Runner welding machine yesterday.I got it home, got it assembled, Installed a 50A x 40 ft power cable (that will allow me to reach anywhere in the garage, and 35 ft outside the garage) 4x6awg cable.I am an accomplished TIG welder on mild steel and stainless, I have certifications with 17 contractors in the area as a tube welder. I'm a Journeyman Boilermaker, so that is what I do.I have never welded Aluminum, so today begins a new journey for me.I got some TIG wire, 1/16a" 4043 to practice with. I will be using 100% argon.2% thoriated tungsten.Wish me luck...lolBy the way,  have been lurking around here for a week or so, and love the site so far.
Reply:A photo of my very first aluminum weld with the machine, first aluminum weld for that matter.
Reply:I quickly found that I preferred my tungsten sharpened rather than balled or rounded.I had the machine setup like this.95Amp with foot control at about 85amp (I started at 85 and had to run with foot pedal wide open so I bumped it up).Straight Argon at 18 CFH.2% Thoriated tungsten.1/16" 4043 wire.I welcome comments.
Reply:I dont know jack about TIG but that looks fantastic!www.rallyready.com
Reply:What did you think about the puddle differences between mild and the aluminum? Did you find it fairly intuitive or were you surprised?Regards,RobGreat Basin WeldingInstagramBlue weldersRed weldersMy luscious Table DIY TIG Torch cooler
Reply:Grats!Looking good!Buy American, or don't whine when you end up on the bread line.
Reply:Airbag, it looks far from good, I have seen some of the pics on here that are good. Now I'll admit it's ok for a beginner, which is what I am on Aluminum.Robert, the puddle is syrupy... for lack of a better term. Yeah, as soon as I figured out how and where the puddle was going, it was kinda intuitive. I will never be a "stack of dimes" guy. I feed at a much faster dip speed rate. Now this may change when I get some bigger filler wire.WeldingMachine, Thanks for the cheers!I have much to learn with Aluminum, but I will.I also found that I need some 3/32" wire, the 1/16" I could barely keep up with feeding.Another issue that I discovered, is that I am impatient waiting on a puddle to form on Aluminum.I am used to steel forming a puddle almost instantly. I found myself sticking the filler wire in early on more than one occasion.Foot pedal is giving me fits also...lol... I dont use one with mild steel, I have always scratch started with preset amperage.Last edited by Boilermaker374; 01-27-2011 at 04:44 PM.
Reply:Welds look beautiful! When I look at the first and last weld I see what looks like a pin hole at the end of the weld. This is a common issue when welding aluminum. At the end of the weld, just before you distinguish the arc add one more touch of filler metal and this should eliminate the pin hole at the end of the weld,
Reply:Congrates on the new machine.Strive to get comfortable with the amperage set to maximum (or at least well above what you know you'll need) and use the pedal.  That way you can mash it to get the puddle started quickly and then back off as needed.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Here is my second try under the hood with 3/32" rod instead of the 1/16".Much better I believe.Im having a terrible time not getting a hole in the fisheye, I have tried an extra dab, and it still appears when I roll off the amperage... Confused.Comments please?Last edited by Boilermaker374; 01-29-2011 at 01:54 PM.
Reply:Looks OK to me except for your ends..The holes have to go!Once you get to the end go around in circles with your torch about the same size as your bead..At the same time back off the pedal and dip your filler into the end..May take 2 or 3 dips but you want to build a "TIT" instead of the hole..The hole is where breakage starts and it don't take long.....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:Thank you, I will give that a shot.
Reply:Here is my third set, I am getting pretty comfortable with stringer beads, now to some joints.
Reply:Those look great. You'll be on your back tigging uphill and upside down next. Thanks for the description on the puddle, I think statements like that can be of great help to others getting to know the materials.Regards,RobGreat Basin WeldingInstagramBlue weldersRed weldersMy luscious Table DIY TIG Torch cooler
Reply:Originally Posted by Boilermaker374I quickly found that I preferred my tungsten sharpened rather than balled or rounded.I had the machine setup like this.95Amp with foot control at about 85amp (I started at 85 and had to run with foot pedal wide open so I bumped it up).Straight Argon at 18 CFH.2% Thoriated tungsten.1/16" 4043 wire.I welcome comments.
Reply:The plate is about .083" x 20"x 2" at it's short end, it's a triangle type piece of scrape I had laying around.It's a piece of an old highway sign.
Reply:Boilermaker374, I myself am a Boilermaker (L.U 667) and as such haven't had much experience with heli-arc on aluminum. I don't have an AC setup with HF so as it stands in my shop all I have is a spoolgun linked to my Lincoln 140C. But from welds I have personally seen done with aluminum TIG, that last set of stringers you posted in your pic looked pretty da*n good. Keep it up and welcome to the the WeldingWeb site! Miller XMT-3502 Lincoln Power Mig 140C (One w/ dedicated spoolgun)Jackson NexGen / Miller Digital EliteMiller S32P SuperWeldcraft 17fv & 9fv Tig TorchVictor & Purox O/ALincoln Ranger 9Fairly Cold Beer!!
Reply:Thanks JLE-ENT!
Reply:Your ends are much better now just try to get them "Round".....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 zapsterYour ends are much better now just try to get them "Round".....zap!