Welding two different aluminum alloys

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Hey guys, I'm not really sure which alloys we are welding right now, but they are both aluminum..... We are currently building something called a Sea Bus which is used as a public transit boat, carrying transit users across a "quay" to a bus station. And basically we have been doing very basic flat/horizontal welds as of right now.Our common problems are; craters and crater cracking, bulky start stops and lack of fusion.I find for lack of fusion, if I go forward and back (almost like a whip pause) in a very tight manner is tends to wet in nicer, but it makes for a larger weld, which is not always accepted openly.But my heat seems hot enough..... my wire speed seems good.... sounds like the bacon on the frying pan... Other welders have setup my machines for me.... And I am running into problems likecraters at the end (which I am told, I should not tack over top of)crater cracks (cracks in the craters)and bulky start stops..... clearly my fault....... lack of experience I guess....Any suggestions??
Reply:more information is needed. what is the basemetal. what is the filler metal. what are your amp/volt settings, what is your shielding gas, are you working to a code?
Reply:Originally Posted by qaqcmore information is needed. what is the basemetal. what is the filler metal. what are your amp/volt settings, what is your shielding gas, are you working to a code?
Reply:For 5083 to 6061 the "Bible" reccamends ER5356 filler. And for your settings see if you can get spray transfer. You should be able to at 25.x volts or whatever your running. If the 6 on the spoon gun means 600IPM then back it down until you get spray transfer not that bacon in a pan sound. What size filler are you running. If your welding lots of 1/4 and stuff 3/64" filler would probably be a good size. --Gol'
Reply:Originally Posted by chroniceliteOoops sorryI am welding 6061 to 5083 using a wire spool gun... not sure what alloy the spool is.... I am using Argon (35 PSI) running at around 25.5 V / 6 (WFS) give or take......We are building a sea bus for the state to be riding on every day, so everything must be inspected and passed by a state certified inspector. Our welds must be between 1/4" to 3/8" Sorry I will have to get back to you on which type of wire spool we are using.... But maybe you can suggest a certain spool ?
Reply:Originally Posted by Go1lumFor 5083 to 6061 the "Bible" reccamends ER5356 filler. And for your settings see if you can get spray transfer. You should be able to at 25.x volts or whatever your running. If the 6 on the spoon gun means 600IPM then back it down until you get spray transfer not that bacon in a pan sound. What size filler are you running. If your welding lots of 1/4 and stuff 3/64" filler would probably be a good size.
Reply:Originally Posted by Rojodiablo6061 to 5083 which I assume is the outer hull sheet, more exposed to the water, and has bends, correct?? I have used 5356 many times for that combo. Can you show us a pic or 2 of the welds, and what thickness are the materials you are welding on??
Reply:Originally Posted by chronicelite.But my heat seems hot enough..... my wire speed seems good.... sounds like the bacon on the frying pan... Other welders have setup my machines for me.... And I am running into problems likecraters at the end (which I am told, I should not tack over top of)crater cracks (cracks in the craters)and bulky start stops..... clearly my fault....... lack of experience I guess....Any suggestions??