Some help needed, Tig welding aluminum for the first time.

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I own a chassis shop in colorado.  I have to mount an alumnium intercooler and weld the charge pipes together on my current job in the shop.  I have never welded alumnium before, all I mainly do is weld chromoly tubing.  I just bought a new miller 200 dx dynisty welder, in fact its showing up tomarrow.  Im interested in a base line setup for my welder as far as amps are concerened.  Should I be concerend with tring the pulse tig right off the bat? What is the best rod to use for 6061 alum.  The welding i have to do to the inter cooler is a corner weld with materials both 1/8" thickness.  the charge pipes will be a butt weld all the way around 4" tube, .065" thickness.  I'm going to do a lot of pratice, but i really have no idea what to set my machine at for this stuff.  I have a gas lense too, should i use it and what argon flow.  I know im asking a lot, but any help would be greatly appreciated.  ThanksTom Rockwell Race Carswww.trracecars.com
Reply:Gas lens yes.130 to 150 amps on 1/8" set on AC of course.70 to 80 amps on the thin stuffPure argon 13cfhTungsten 3/32 - Lanth. Do not use pure on Inverter machine.Bal approx 72, a little less on the thinner tubeFreq 130hz or so. You did not state outside or inside corner.Foot pedal I assume.Filler 3/32 5356 on 1/8" and 1/16" 5356 on the thin tube.Post flow about 8 to 10 seconds, make sure the tung. does not turn blue after you weld. If it does, regrind and increase post flow time.T.J.www.tjsperformance.comDynasty 300 DXHTP 240HTP Microcut 380Hyperthem 85JD2 Hyd Bender and HF Hyd Ring Roller all in one =(Frankenbender)Bpt. Mill/DRO4' x 8' CNC Plasma TableInstagram: tjsperformanceYT: TJS Welding and Fabrication
Reply:Form a ball on the end of the tungsten before weldingI think 3/32 would be large enough but try and see.I would use the 4043 filler wire but the 5356 will be ok too. Slightlly more corrosion resistance.If you are welding very close to that intercooler it could get very hot.You might want to clamp some heat sinks in between the cooler and where you are welding. Do a test section first. The sections need to be tacked in 3 or 4 spots before finish welding. Make sure to use a stainless brush on the area to be welded.
Reply:Originally Posted by Donald BranscomForm a ball on the end of the tungsten before weldingI think 3/32 would be large enough but try and see.I would use the 4043 filler wire but the 5356 will be ok too. Slightlly more corrosion resistance.
Reply:Thanks guys.  I got my machine and tried alum for the first time with very good results.  Thanks very much.Tom Rockwell Race Carswww.trracecars.com
Reply:What, no picts?! Just stop teasing us.
Reply:I'll post some pics when i get the intercooler done,  I just tried some pratice beads to see what it was like.  I should have some pictures by the end of the week.Tom Rockwell Race Carswww.trracecars.com