How can I improve these aluminum welds?

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Hey everbody, I'm new to the forum and I'll be here for a looong time. Anyway, could you give me some tips on improving these GTAWed aluminum parts. Any constructive feedback would be greatly appreciated. Thanks in advanceThese were welded using a 3/32 pure tungsten electrode with a size 6 gas cup on AC current at 110A. 100% Ar shielding gas was supplied at 15 cfh.Here I really didn't know how to tackle the transition from fillet to butt
Reply:What machine are you using and filler type and size. Also what was your balance set at.The welds don't look to bad but I am still learning myself.Miller DVI2Lincoln Precision Tig 225Thermodynamics Cutmaster 38Everything else needed.
Reply:I'm using a Miller Synchrowave 250DX set at balanced welding. The filler was 3/32 4043. The base of the cone was beveled with a 1/16" root face so I figured biasing the balance towards more penetration wasn't necessary - or was it?Just trying to make my welds look and operate the best they can.
Reply:they actually look pretty good. Might try laying the pipe/flange assembly on its side while welding it so you can go vertical up on the fillet and transition into the butt weld in the flat position. Should help you to "end comfertable" as they say and handle that tough transition better. Have to weld it in 1/4s unless you are ninja enough to continue on to the next fillet vert down.
Reply:Try some 1/16" 4043..Less is more.I did this whole thing with 1/16"Same but different from what you are doing..http://weldingweb.com/vbb/showthread.php...ghlight=Intake...zap!Last edited by zapster; 03-31-2010 at 06:27 PM.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:I would say the weld looks good.Try some of the advice already given, (position & filler size). It'll be a bitch to get a bolt head to torque down flat to the flange with the bead in the way.One question though; Why are you using pure tungsten?Unless you are using an old transformer machine, you should be using anything other than pure.Last edited by papabear; 03-31-2010 at 08:33 PM."SOUTHPAW" A wise person learns from another persons mistakes;A smart person learns from their own mistakes;But, a stupid person.............never learns.
Reply:Originally Posted by zapsterTry some 1/16" 4043..Less is more.I did this whole thing with 1/16"Same but different from what you are doing..http://weldingweb.com/vbb/showthread.php...ghlight=Intake...zap!
Reply:to tackle the transition, you may want to run the butt welds separately from the fillets.  a butt weld is going to require less heat than a fillet.