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I'm pretty new with welding in general and still have a lot to learn so please don't criticise to bad. I bought a tig setup (HTP Invertig 221) fresh out of school and have had some issues welding aluminum after spending a lot of time trying to figure out these frequency and balance settings i wasn't use to i was finally able to weld a solid bead. and at first i didn't think much of the texture i was getting figured it was just the material but every time even on different pieces of aluminum from diffrent all of them have had this texture almost like someone threw sand in the molten metal.I've tried everything i can think of, different methods of cleaning whether it's a brand new stainless brush, scotch brite, sand paper, all with and without acetone afterwards. Different tungstens. A big variety of different alumina cups and gas lenses. I've raised and lowered the gas flow , and played with the frequency and balance both ways up and down until i wouldnt weld, And in the end still the same outcome. so i figured it was the cheap filler rod i bought from weldingcity even despite when i asked a few guys and they said filler rod was filler rod. so easy to check that i'll fuse 2 pieces together, same outcome (see last pic) still this sandy texture. Especially with me being so fresh at this idk what to do or what else to try or think weather it's me not knowing enough of what i'm doing, defective welding machine, bad gas regulator causing bad gas flow or possibly a bad batch of argon? please help first 2 pics are with filler last one was a fusion without filler Attached Images
Reply:What's your base material? Filler material? What are your machine settings?-Chris
Reply:Originally Posted by Mr. SmithWhat's your base material? Filler material? What are your machine settings?
Reply:Do this. On a scrap piece of 6061, get a clean puddle (enough cleaning to not get any pepper specks), then add a single dab of your filler rod. Look VERY closely at the tip of the filler rod the instant it hits the puddle edge----if you see anything other than the filler turn into clean, silvery molten aluminum, you have contaminated filler rod. Do this a couple of times and really focus on the tip of the filler right as it melts into the puddle. If you see any contamination, you might get away with extra cleaning of the filler with acetone, scotchbrite, then acetone again. You'll get some black smut regardless, but you need a good, clean acetone-soaked rag to the point where you get very very little black smut coming off the filler. 1st on WeldingWeb to have a scrolling sig! HTP Invertig 400HTP Invertig 221HTP ProPulse 300HTP ProPulse 200 x2HTP ProPulse 220MTSHTP Inverarc 200TLP HTP Microcut 875SC
Reply:Been there done that. It's piss poor anodized aluminum. And cheap at that. A combination of dirt, and more dirt (anodizing) is what caused that.Miller Dynasty 200DXMiller Spectrum 250DMiller Millermatic 200Bunch of old blue dinosaurs....
Reply:You are overheating the material. That is typical of someone running too low of an amp setting and having to wait too long for the puddle to form. The silicon in the 4043 is coming out because the bead isn't cooling fast enough.With alum being such a good heat sink, you need to crank up your amps so you can get the puddle to form instantly. On 1/8" alum you want to be at at least 150 amps. I prefer 180-200 myself. We set the machines at 150 for students because they can't back down on the pedal as fast once the puddle forms and it makes it a bit easier on them, but when possible I will turn it up on them as well if they can handle it..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Originally Posted by OscarDo this. On a scrap piece of 6061, get a clean puddle (enough cleaning to not get any pepper specks), then add a single dab of your filler rod. Look VERY closely at the tip of the filler rod the instant it hits the puddle edge----if you see anything other than the filler turn into clean, silvery molten aluminum, you have contaminated filler rod. Do this a couple of times and really focus on the tip of the filler right as it melts into the puddle. If you see any contamination, you might get away with extra cleaning of the filler with acetone, scotchbrite, then acetone again. You'll get some black smut regardless, but you need a good, clean acetone-soaked rag to the point where you get very very little black smut coming off the filler.
Reply:Another thing to try is switch away from 4043 to 5356 and see if the weld cleans up. Sure does not look like a gas issue to me. Like DSW said, the mottling looks like silicon migration from the 4043 filler.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:Originally Posted by shovelonAnother thing to try is switch away from 4043 to 5356 and see if the weld cleans up. Sure does not look like a gas issue to me. Like DSW said, the mottling looks like silicon migration from the 4043 filler.
Reply:Originally Posted by thebadz32seems like when i read up on filler metals the 4043 was going to be best for my application being around cars and in engine bays. However i don't think the filler metal has anything to do with the rough texturing as the fusion weld without filler rod (to test my filler rod theory) did the same thing, same texture.
Reply:Double the amps, 50% balance, cleaner tungsten. 5356 filler. Betcha it looks better.SqWave 200Millermatic 190Airco 200 ACHypertherm PM45Boice-Crane Band SawVictor O/A
Reply:To add to what DSW and Shovelon are stating you need to really move fast on aluminum and not go slow. Hot and fast is the key then you will get the creamy weld look. Looks like silcone floating to the top to me as well. 5356 too.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:Originally Posted by BrazinDouble the amps, 50% balance, cleaner tungsten. 5356 filler. Betcha it looks better.
Reply:If you're just trying to figure out what's wrong with your set up 50% is a great place to start because it's impossible to get wrong. I've seen pictures where people are trying to minimize the electrode negative but they haven't got their material clean enough for that game. Walk first, then run.SqWave 200Millermatic 190Airco 200 ACHypertherm PM45Boice-Crane Band SawVictor O/A
Reply:Lately on my Dynasty I have been upping the balance more and more. I was first using 72-74. Now I have been using 80-82 or so after reading some of BC's posts. The OP material does look fairly clean so a higher Balance should be good.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:Which tungsten did you use to produce the beads in the photos?
Reply:Originally Posted by thebadz32I'm pretty new with welding in general and still have a lot to learn so please don't criticise to bad. I bought a tig setup (HTP Invertig 221) fresh out of school and have had some issues welding aluminum after spending a lot of time trying to figure out these frequency and balance settings i wasn't use to i was finally able to weld a solid bead. and at first i didn't think much of the texture i was getting figured it was just the material but every time even on different pieces of aluminum from diffrent all of them have had this texture almost like someone threw sand in the molten metal.I've tried everything i can think of, different methods of cleaning whether it's a brand new stainless brush, scotch brite, sand paper, all with and without acetone afterwards. Different tungstens. A big variety of different alumina cups and gas lenses. I've raised and lowered the gas flow , and played with the frequency and balance both ways up and down until i wouldnt weld, And in the end still the same outcome. so i figured it was the cheap filler rod i bought from weldingcity even despite when i asked a few guys and they said filler rod was filler rod. so easy to check that i'll fuse 2 pieces together, same outcome (see last pic) still this sandy texture. Especially with me being so fresh at this idk what to do or what else to try or think weather it's me not knowing enough of what i'm doing, defective welding machine, bad gas regulator causing bad gas flow or possibly a bad batch of argon? please help first 2 pics are with filler last one was a fusion without filler
Reply:Oh I've also seen this before to, contaminated bottles, if some one or a company took a 75/25 or other mixture bottle and tried to stick straight argon in it, it don't work it does look a bit like a contaminated gas problem also..
Reply:Originally Posted by Mark's WeldingRead quite a few of the responses on here to your guestion, one response which I hadn't seen thou is this and it happen to me on a test, if your welding thin aluminum you have to make sure the inside is as clean as the outside because with you puddle it, it will pull the dirt thru from the other side.. I and the company I tested for learned this because they never took the plastic backing off of the test plate I was welding on, I never looked until this **** just wouldn't weld, so make sure both sides are clean, try an use brake clean what I use and a good stainless steel wire brush because steel will contaminate it. Good luck let me know how you make out, I also do aluminum trans and pto case repairs and castings now will lots of good results using a Miller dynasty.
Reply:Originally Posted by thegaryI would not use brake clean. When brake clean is superheated like when welded on will create fosgeen gas, which is deadly with one breath. If the brake clean has not completely evaporated like if it is in a crack is when this can happen. There have been a few people die from this.
Reply:Originally Posted by brandonsmashThe more you know. . .Seriously, phosgene is bad juju.http://www.popsci.com/diy/article/20...t-get-careless |
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发表于 2021-8-31 22:19:06