how do I fix this?

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Reply:miller 210 mig with 3035 spoolgun, 35 wire 4043, welding 6061.  problem is when i get to the end of the bead it blows out the piece I am welding.  tried different feed and power settings with no luck.
Reply:Hello tnc110, with lesser featured welders you have a couple of options. Either you include a run-off tab to keep the end of the weld from blowing out and then bust the tab off and finish the edge with a grinder/file/sander or other finishing tool, or you weld from both edges to the middle or some variation of that. On more advanced aluminum welding systems, they have a crater-fill feature that allows for ending welds on edges and tapers off the volts/amps to prevent such a condition. That's the quick answer and others may have additional suggestions. Best of luck and regards, Allanaevald
Reply:Let the material cool! It looks like the 3rd weld, it must have been hot.
Reply:Runoff tab.Tack a piece of similar thickness material so that when you are at the end of the joint, you are welding on the tab.  When done, break it off.
Reply:Runoff tab or no runoff tab, until he learns to mig weld aluminum, he's going to have problems.I see, in the photo, everything from too hot to flat cold.Learn to weld aluminum first and then worry about ending the bead.  Lots more hood time in order here.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:Originally Posted by SundownIIIRunoff tab or no runoff tab, until he learns to mig weld aluminum, he's going to have problems.I see, in the photo, everything from too hot to flat cold.Learn to weld aluminum first and then worry about ending the bead.  Lots more hood time in order here.
Reply:i dont use my 30a that much but heres the last timemiller has a vid. on mig welding alum.and look on you tube Attached Images
Reply:The settings on the welder are just to get you in the ball park. Final adjustment is up to you.
Reply:looks real hot or not enough wire. I know on my miller 251 my wire speeds are all about 20% higher than they recommend for a given voltage. I would turn up the feed speed and get some more filler in there