Help Needed with TIG Welding Aluminum

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I searched but maybe I'm too new to know what info is helpful in my situation.Our lab manager left recently and while he was here, he insisted on doing the welding that needed to be done.  Now that he's gone, no one has any decent experience with TIG welding aluminum, and we need to weld some 3003-0 AL.  I've done this weld before, but I don't know what the machine was set on. They already had the machine set up for me.  He has stickers on the settings that say TIG Steel or TIG ALUM, but something must be off because it's not working.  It's burning and blowing away or making it yellow and porous.What am I going to set everything to on a Miller Dialarc HF Tig welder?This is what I have so far:Tungsten tip (green end) ground to cone pointHigh frequency set to continuousRemote amperageAC current set to 140-310 (the highest)Any advice / corrections?  Thanks->Project Thread - 98SS BaggedAir Ride Questions Answered on AirRideTalk.com!!!DOT PTC FittingsDOT Compression FittingsAdaptersDOT Airline
Reply:What are you using for gas?Just my  opinion, not from a book, just from the road.Howes Welding Inc.www.howesweldinginc.com
Reply:i've never even heard of 3003 aluminum..let alone weld it.. how thick is this material..we have to start somewhere...and green end tungestion?i use red end only...you don't mention what you're using for gas...yellow crap = contamination..now we have to figure out where its coming from...lets get down to the specifics......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:sounds like you are having either a gas issue or a dissimilar metal issue, make sure your gas is on and you are using either pure argon or a mixture of argon/helium, and make sure you have a aluminum filler wire, 4043 is the recommended filler for 3003, you can also use 1100Welding 3003 is the same as welding any other aluminumA/Ccontinuous H.F.pure or 2% thoraited or Ceriated tungsten ( your preference)if you got a a/c balance knob set it to around 7 or 70gas is on, and can hear it coming out torchcorrect filler materialbench is groundedmaterial to be welded should fairly cleanLast edited by elderthewelder; 09-29-2006 at 06:34 PM.
Reply:Elder is right, seems like a gas issue. Green tungsten will be fine. Your gas should be around 30-35 cfh or 15-20 if using a water cooler. Hope you've got it now.Bill
Reply:Originally Posted by zapsteri've never even heard of 3003 aluminum..let alone weld it.. ...zap!
Reply:naaaaaaai dont do sheet aluminum  i only do chassis and rollcages.......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:Only "fairly  clean?" You must lead a charmed life . I was taught in my navy welding apprenticeship , that it had to be sanitary -I say STERILE -to be sure each time -for tigging aluminum and use the correct size tungsten with a balled end , except for very small tungstens & thin aluminum. thin alum  use argon , thick alum  use helium or mix[SIZE="5"Yardbird"
Reply:Hey guys, thanks for the replies.It was the gas.  Now, this is going to sound stupid, but trust me, you'd have to see this. The rig isn't mine and I was unaware that the gas valve knob had such a hard spot in it that you have to overcome to actually open the valve.  I had just turned it until it stopped and didn't think to check the gas flow.   I had started thinking about it after posting this and thought about checking the gas.  Sure enough, giving the valve knob some umph to overcome a hard spot, the valve actually opened and the gas started flowing.  I know it sounds stupid but the knob turned a good bit before it hit the hard spot, so I assumed it opened the valve.It's doing great now.  The material I'm welding is 3003-0 temper aluminum tubing in .065" wall thickness.  I'm doing what we call pinch welding for test parts in our lab.  We place an inch or two of the tube in a vise and close it until the end of the tube is flattened and then weld the seam shut.    I did a handful of parts last week and for ****s-n-giggles, I burst tested them.  One blew at 800 psi, two at 1500psi, one at 2200 psi, two at 2500 psi, and one at 2700 psi.  One of the 2500 and the 2700 blew out the side of the tube and not the weld.  Gotta keep practicing to get consistent, but at least I know I can do this.  I knew I could, just haven't had that much experience or practice.->Project Thread - 98SS BaggedAir Ride Questions Answered on AirRideTalk.com!!!DOT PTC FittingsDOT Compression FittingsAdaptersDOT Airline
Reply:practice,  practice,  practice,  practice is the key, well now that the gas is on any way. good luck and stick with it it will all be second nature soon. 8^)) summer is here, plant a tree for mother earth. if you dont have time or space, sponcer some one else to plant one for you.feel free to shoot me a PM or e-mail me at [email][email protected] i got lots of time.
Reply:Thanks.  I wish I had a TIG at home so I could practice all the time.  I have to use this one at work when I manage to get a few minutes to myself.  Thanks again guys.->Project Thread - 98SS BaggedAir Ride Questions Answered on AirRideTalk.com!!!DOT PTC FittingsDOT Compression FittingsAdaptersDOT Airline
Reply:yep having one at home to play with would realy help. maybee you could talk the boss into helping you buy one to improve your tig skills for the job, after all you would be practising on your time so it might be doable. the TA-185 is a cheap option at under $2000.00 if $$ is realy tight maybee consider a ryland i think there 200 amp TIG is like $1000 and the guy i made a cover for said he realy liked his. for practice it might be werth a try especaly if you can get the boss to foot the bill, or maybee part of the bill.could be werth looking into, after all all he can say is no, not like he would fire you for offering to use your home time to improve your job skill. 8^)) summer is here, plant a tree for mother earth. if you dont have time or space, sponcer some one else to plant one for you.feel free to shoot me a PM or e-mail me at [email][email protected] i got lots of time.