Hate when this happens

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The entire thing came along perfect until this happened. Cleaned the egdes with sandpaper and acetone. GRRRRRRRBut luckily I fixed it and you can hardly tell. Anyone know a reason why this happens? I swear it only happens on this one product I make. Everything else (same joints, settings etc) it never happens)Haven't found a great way to clean all the edges after it comes off the cnc table. Seems to be hit or miss. Tried flap wheels, DA sanders, acetone & sandpaper.Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:I see dirt all along the weld . Perhaps sand got embedded along with resin in the metal and did not lift out with the acetone?I use a file on the edge before acetone.Last edited by shovelon; 11-05-2015 at 09:02 AM.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:Even with a da sander it never seems to get it all before its tacked togheter. Most of the time I have better luck not cleaning it. I haven't even owned acetone for the past year or two. I use it and get these issues.Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:http://www.aircraftspruce.com/catalo.../alumiprep.phpHead down to your auto paint store to buy some.. cheaper ways too, but this is a place to start..Last edited by Brand X; 11-05-2015 at 09:45 AM.Esab/Lorch ET-220iEsab 160i caddyThermal LM-200 Lincoln feedersThermal Pee-Wee 85sThermal 60i- 3phase /RPC powered (Beast)Thermal Drag-gun 35CINE 1500 Klutch 140i
Reply:Sandpaper could be your problem, prepping with any power sander or wire wheel could smear oxide into the surface rather than remove it. Use red scotchbrite or a stainless wire brush and prep by hand, clean any dross off the edges with a file then brush and wipe with acetone. All that black crud in the weld is contamination that is floating up.
Reply:As the others have eluded to Gamble, cleaning is the issue here. There is something that is off-gassing as you are welding and causing the holes. The black stuff on the surface is likely something that has been consumed/burned in the arc and the "carbon" has floated to the top of the puddle. The type of sand paper used can be an issue as well. I can't remember which grades are no-no's right now but there is a difference. One additional item even after you have cleaned with acetone another wipe-down with alcohol will help. Good luck and best regards, Allanaevald
Reply:Originally Posted by Brand Xhttp://www.aircraftspruce.com/catalo.../alumiprep.phpHead down to your auto paint store to buy some.. cheaper ways too, but this is a place to start..
Reply:I agree with the hand file or single flute carbide bit for aluminum.
Reply:I took one look at the picture and said to myself..." Don't look very clean to me".....Stay away from anything that has to do with "sand" when it comes to cleaning especially with aluminum...How long have you been here again?...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:That weld is way dirty. I cut this with a carbinmindium cut off wheel on a 4.5 inch grinder then went over it lightly with a carbide burr, of course with no oil on the burr
Reply:"Wondering if part of this could be the solution mixed in with the water table when it's cut on the cnc. "Unquestionably, any and all particles and solutions from the cutting process MUST be removed! Not just from the joint, but the entire HAZ plus a good margin.Be wary of The Numbers: Figures don't lie,. but liars can figure.Welders:2008 Lincoln 140 GMAW&FCAW2012 HF 165 'toy' GTAW&SMAW1970's Cobbled together O/A
Reply:Looks like your not getting enough cleaning around the whole weld either
Reply:Originally Posted by zapsterI took one look at the picture and said to myself..." Don't look very clean to me".....Stay away from anything that has to do with "sand" when it comes to cleaning especially with aluminum...How long have you been here again?...zap!
Reply:How clean is your acetone?I put some in a coffee can and use it out of that can ONLY.If you just keep putting a rag up against the acetone can and soaking the rag that way all you are doing is contaminating the whole gallon..quart whatever you get.Never use acetone out of the container it came in..Put some in something else first and keep it clean...It's the small things that don't seem to matter that add up to big problems that do.......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:how long have you been here again?...zap!
Reply:I used to work for a weldingcompany that made aluminium piping for the nuclear industry (uranium enrichment)Needless to say that every weld was 100% Xray.The bevel was done with a file, and the outside of the pipe was also cleaned with a file.For the inside of the pipe we used a scraper deburring tool. http://www.ebay.com/bhp/deburring-tool-setEvery tool that we used was only used for aluminium never for other materials to prevent "contamination".We never used sandpaper, acetone was almost never used.Last edited by bluemoon; 11-05-2015 at 03:42 PM.
Reply:It's so strange. Cut some pieces just now and cleaned them as normal. DA sander. Welded beautifully. No black **** floating to the top.It's not consistent at all. Sometimes yes and sometimes no.  Same sandpaper as before. I typically try to keep it for aluminum only. I'm going to do a test and dunk one piece into the water on the water table, clean it then weld it and do one that doesn't touch the water. Up until a few months ago I did water only, now I added washing soda. So will report back to see if it has any bearing on itTorchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:What size cup are you using? What gas flow? When pulling the filler rod from puddle, are you pulling it too far, out of gas shield while still hot/molten?  If degassing the hot filler and then re introducing to puddle it could be the source of contamination.Miller TrailBlazer 251Miller HF-250-1Miller MaxStar 150 STLHyperTherm PowerMax 380 plasmaLincoln PowerMig 180Millermatic 252Miller Diversion 180
Reply:Was told not to use red Scotch brite, it's Aluminum Oxide, green is not supposed to be.
Reply:Stainless wire brush is all I use.12v battery, jumper cables, and a 6013.I only have a facebook page. https://www.facebook.com/pages/VPT/244788508917829
Reply:Originally Posted by mcostelloWas told not to use red Scotch brite, it's Aluminum Oxide, green is not supposed to be.