TIG welding with 75% AR/ 25% HE

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Disclaimer:Ive only been welding for two years.  I attended a junior college welding program. I recently certified AWS D1.1 (3G) using 7018 on 3/8" A36 plate, but have no qualifications welding aluminum.After watching a video from Weldingtipsandtricks.com, where Jody discussed using Helium mixed in with Argeon, i decided to try it.  I purchesed a pre-mixed cyclinder of 75% Argon and 25% Helium and ran a few tests.The tests were completed using a Miller Dynasty 280DX, on AC (Test#3 was DC). The water cooler used was a Miller Coolmate 3. The torch used was a water cooled torch with a #6 Alumina cup and a gas lens (CK2325SF/ SLWHAT-35 & 225HCLV/ Torch Pkg 300a Rg w/25' SuperFlex Cable). The metal used was two pices of (1/4") 6"x4"x2" square tube of 6061 Aluminium. One fillet weld and one edge weld was completed for each test. Each test was started with the test metal slightly warm to touch. For further depiction of tests and specific welding parameters used, see photos bellow.Lessons learned:Welding with 25% helium and 75% Argon gas made for more comfortable weldingg experience. The puddle materialized quickly and flowed smootly. The arc was easy to start and maintain. Welding with 100% Argon was not as comfortable. The heat from the metal with the machine set at 230A was uncomfortable (not from the torch body mind you, but the metal). With straight Argeon the amps needed to be increased by 40 amps to get a good puddle started and maintain good root penetration on the fillet weld. Conclution: Is it worth using Argon/ Helium on 1/4" Aluminum? It depends on the machine used, but given the testing parameters used, I think so. Reducing the amps the machine puts out increases the duty cycle and the heat generated. The weld quality was very simular, but getting there was different in my experience. I also tried the AR/HE mix on A36 steel. I was able to reduce the amps by 20 amps.  GarTest #1 (75% AR/ 75% HE) @190 amps:Test #2 (100% Argon) @230 amps:Test #3 was completed on A36 steel on DC.Lincoln Electric, Power MIG 256Hypertherm Powermax 45 Miller Dynasty 280DXSmith O/A torchGenesis of a welding table
Reply:Yah the pros use it for a reason. What did the cylinder cost?
Reply:Nicely done!
Reply:My last refill I got the helium mix as well. There Is a noticeable difference in heat output.  How much was the cost difference for you?Thermal arc 211iCk flex-loc 150 & 130Clamps, saws & grindersHarbor freight 80 amp inverter
Reply:GarGood work - great photo quality - and even better documentation.Opus
Reply:Very nicely done Gar Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Thanks for the kind words. The cost of the cylinder was $217 for a 150 CF (S) type cylinder. First fill with 75/25 Ar/He was half off and cost $32.  Just did a quick internet search and located this, seems to be info on the various gas mixes and their intended uses:http://cryogenservice.com/catalog/ga...ding-mixtures/GarLincoln Electric, Power MIG 256Hypertherm Powermax 45 Miller Dynasty 280DXSmith O/A torchGenesis of a welding table
Reply:Nice job.Great beads.  I saw you turned up the CFH for the helium, but do you normally use 25 CFH with argon?
Reply:Fantastic analysis Gar, was this ballon grade helium?
Reply:Originally Posted by GarThanks for the kind words. The cost of the cylinder was $217 for a 150 CF (S) type cylinder. First fill with 75/25 Ar/He was half off and cost $32.  Just did a quick internet search and located this, seems to be info on the various gas mixes and their intended uses:http://cryogenservice.com/catalog/ga...ding-mixtures/Gar
Reply:gar; no disclaimer needed. those are some nice welds. if i can figure out how to get my 300cf argon cylinder up my rickety basement steps i may swap it out for 2 smaller ones. 1 of argon one of mix.i.u.o.e. # 15queens, ny and sunny fla
Reply:Good comparison. Nice welds too. Nicely done!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 Drf255Nice job.Great beads.  I saw you turned up the CFH for the helium, but do you normally use 25 CFH with argon?
Reply:Gar,Pretty nice look'n work.   Now if you would have gone back and laid another short bead in there to wrap that corner it would have really looked professional.
Reply:Thanks for taking the time and effort to do this comparison plus document your findings.Lincoln SA 200Esab Caddy 160Thermal Arc 201TSMiller Dialarc HFI don't like making plans for the day because then the word "premeditated" gets thrown around the courtroom....
Reply:Originally Posted by dubl_tThanks for taking the time and effort to do this comparison plus document your findings.