First Alum. TIG test

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I tried TIG bead running on aluminum last night.Here's the setup:Bobcat 225G, driving a Miller HF-251D, straight Argon gas, 1/16 Lanthanated electrode, 3/8 (#6?) cup. The workpiece: A piece of 1/8" thick aluminum bar stock, 1 inch wide, 3 feet long. Cleaned, wire brushed with a new SS brush, and wiped with acetone.As awful as you can imagine it, it was probably a bit worse.The settings:75-110 amps, (with a remote rheostat pedal).The HF starter worked like a dream. The arc was a bit unstable, but that may be normal with AC.  The arc would start, and I would move a bit, then slowly increase current until the Alum. would start to melt into a puddle, and then I'd promptly blow a hole in it.Butt test: The aluminum would never flow together. Melt, but never flow. Blowing spatter.I'm going to try again tonight. (The Argon bottle (20lb) was at around 400lbs and ran empty quick.) It had also been sitting for about 6 years. Been that long since I wirefed aluminum.Looking for advice. I think that my gas flow was too high. I will be purchasing a better flow meter today from the local shop when I get the bottle refilled. I need a second regulator/flowmeter anyway. -az-
Reply:Butt welding aluminum is pissin' into the wind. Use filler metal.For 1/8" material I would use a minimum 3/32" tungsten and a #8 cup....but that's just me.YMMVRex
Reply:Originally Posted by RedneckJazzI tried TIG bead running on aluminum last night.Here's the setup:Bobcat 225G, driving a Miller HF-251D, straight Argon gas, 1/16 Lanthanated electrode, 3/8 (#6?) cup. The workpiece: A piece of 1/8" thick aluminum bar stock, 1 inch wide, 3 feet long. Cleaned, wire brushed with a new SS brush, and wiped with acetone.As awful as you can imagine it, it was probably a bit worse.The settings:75-110 amps, (with a remote rheostat pedal).The HF starter worked like a dream. The arc was a bit unstable, but that may be normal with AC.  The arc would start, and I would move a bit, then slowly increase current until the Alum. would start to melt into a puddle, and then I'd promptly blow a hole in it.Butt test: The aluminum would never flow together. Melt, but never flow. Blowing spatter.I'm going to try again tonight. (The Argon bottle (20lb) was at around 400lbs and ran empty quick.) It had also been sitting for about 6 years. Been that long since I wirefed aluminum.Looking for advice. I think that my gas flow was too high. I will be purchasing a better flow meter today from the local shop when I get the bottle refilled. I need a second regulator/flowmeter anyway. -az-
Reply:Problem # 1 is that 1/16" will not hold up to the heat you need..Try some 3/32" next time..I use Red...Blowing holes..I suspect that alot of your tungsten is in there also...Like Rojo stated..Start hot then be on the lookout for the dreaded "Drip Zone"..That's when you know you over did it...Before you know it it will be ramp down as the piece gets Hotter and HOtter and HOTTer!!!Seat time will tell..Post some pics so we can see what's going on......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:Oh, I have nothing to add. EXCEPT that aluminum sucks big, green, kelp wads through hookah snorkels. UUUuuuuuuhhhh, all better now. City of L.A. Structural; Manual & Semi-Automatic;"Surely there is a mine for silver, and a place where gold is refined. Iron is taken from the earth, and copper is smelted from ore."Job 28:1,2Lincoln, Miller, Victor & ISV BibleDanny
Reply:Originally Posted by RedneckJazzI tried TIG bead running on aluminum last night.Here's the setup:Bobcat 225G, driving a Miller HF-251D, straight Argon gas, 1/16 Lanthanated electrode, 3/8 (#6?) cup. The workpiece: A piece of 1/8" thick aluminum bar stock, 1 inch wide, 3 feet long. Cleaned, wire brushed with a new SS brush, and wiped with acetone.As awful as you can imagine it, it was probably a bit worse.The settings:75-110 amps, (with a remote rheostat pedal).The HF starter worked like a dream. The arc was a bit unstable, but that may be normal with AC.  The arc would start, and I would move a bit, then slowly increase current until the Alum. would start to melt into a puddle, and then I'd promptly blow a hole in it.Butt test: The aluminum would never flow together. Melt, but never flow. Blowing spatter.I'm going to try again tonight. (The Argon bottle (20lb) was at around 400lbs and ran empty quick.) It had also been sitting for about 6 years. Been that long since I wirefed aluminum.Looking for advice. I think that my gas flow was too high. I will be purchasing a better flow meter today from the local shop when I get the bottle refilled. I need a second regulator/flowmeter anyway. -az-
Reply:Excellent advice! #1 reduced gas flow.#2 Started hot and backed off, Rinse and repeat.Finally got some proper beads, and then learned to travel a bit.Timing is everything. Practice, practice, practice.Practiced dipping the filler rod into the puddle.yeah... without touching the electrode.Exercised my colorful vocabulary some.Thanks for all the great advice. I'm making progress.I'd have replied sooner but my better (and smarter too) half is having gallstone problems, and the tests just seem to go on and on, without any real treatment yet.  Poor thing is doubled over in pain this morning.  Cant do a thing to help her.Friggin Doctors and the health care system can be frustratingly slow, till the bills are sent out.-az-