Aluminum Tig Weld Critique

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So, I have gone through a couple little (G size) bottles since commencing my Tig welding "career" but would like some constructive criticism on how to improve. I have a gut feeling my travel speed may be low. Maybe someone can tell by the picture.In the picture both welds are on 5052 aluminum sheet, about 0.045" thick. Both were done with my Lincoln Tig 175 on AC. This welder only has "auto balance" so I can't adjust the cleaning directly. I wanted to start welding on thin material which may be backwards to what most people do. I love this little welder, except for the 200 lb weight.Small weld:12 cfh argon1/16" 4043 rod1/16" pure tungsten#5 nozzle (I think).about 30 amp on machine (lower while welding)haven't a clue about weld speedLarger weld15cfh argon3/32" 4043 rod (seems a bit large)3/32" pure tungsten#7 nozzleabout 40 amp on machine (around 30? while welding)Thanks! Attached Images
Reply:That looks excellent to me. I agree that going a tad faster will help. Try some 5356 if you have a chance. It tolerates the heat a little better.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:Do you guys think the penetration is ok?  Looks good to me, but I have posted similar welds and was told there's no penetration.Miller Diversion 180Hobart Handler 140 (Soon to be replaced with Miller 211?)Miller Spectrum 625 Extreme
Reply:I'd think with  .045 you'd have no issues with penetration, but I don't see any except a tiny bit on the ends of the 2nd weld. 30-40 amps is probably too low. You are getting away with it most likely because the pieces are so small they heat up on you. General rule of thumb for alum is to set the machine above the 1 amp per .001 rule. For something this thin I'd say you would want the machine set at 55-60 amps and then back down as soon as you get the puddle going and go faster. 10-20% over usually works well to get the puddle going fast.One of the biggest issues I see with new alum tig welders is that they want to run too cold. The back of your thin pieces tells me you are too cold even with the huge beads on the top. A new tig welder should be blowing big holes in material that thin on average if they are doing it right..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 shovelonThat looks excellent to me. I agree that going a tad faster will help. Try some 5356 if you have a chance. It tolerates the heat a little better.
Reply:Yes, I was thinking I was going a too slow which means I could put more current to it.I was trying some more welds today at a higher speed and current and yes, I am blowing holes and filling them as I go. Not so pretty any more! Now all the filler is on the saggy opposite side. This is going to take some time. Definitely still a beginner.I picked up some 5356 here so I will try it.I had another post about how the arc cleaning quit on me and shovelon was right, it was a bad bottle of argon. This forum has been a great resource and the members have great attitudes towards us green guys. Maybe someday I can do something besides ask questions.Rick
Reply:You will find out fast enough that when you reach the end of a weld on thin aluminum you will be using VERY LITTLE pedal anymore..Too much pedal = "Splash" on the floor..Or your foot or leg if you 'aint careful..And that will SUCK....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:I think I am done with the major globs of splat. Just a saggy thing now. No puns!Rick
Reply:What I tell the beginner aluminum welder guys is practice on a little thicker plate as apposed to thinner......I t makes it possible to concentrate on movement and dabbing and not over heating a thin piece of sheet metal ........Then when you get the hang of  it go to thinner material.......Works for me...  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Originally Posted by DSWI'd think with  .045 you'd have no issues with penetration, but I don't see any except a tiny bit on the ends of the 2nd weld. 30-40 amps is probably too low. You are getting away with it most likely because the pieces are so small they heat up on you. General rule of thumb for alum is to set the machine above the 1 amp per .001 rule. For something this thin I'd say you would want the machine set at 55-60 amps and then back down as soon as you get the puddle going and go faster. 10-20% over usually works well to get the puddle going fast.One of the biggest issues I see with new alum tig welders is that they want to run too cold. The back of your thin pieces tells me you are too cold even with the huge beads on the top. A new tig welder should be blowing big holes in material that thin on average if they are doing it right.
Reply:I think I have the start of the weld figured out. You have to wait for it to open up pretty good, using a good amount of current so it happens quickly, move the torch out of the way and stick the rod in and GO!. It all happens quickly so the only way is to practice practice practice, just like a guitar.At first I thought it might be harder to learn on thin metal, but now I am not so sure. I went out and bought a 2' x 3' sheet of 1/8" 5052 and I have found it is harder to weld than the thin material. I won't post any pictures of the 1/8" welds because it looks like I was making a sieve. I have started to wear my work boots now too to avoid the globs descending to the floor Ha ha. I'll get it but I am going to need a lot of these little bottles of gas. I am thinking I should have leased a big bottle to learn with then bought this little bottle that I own.Thankfully aluminum filler rod is cheap.Rick
Reply:Get the biggest bottle you can. Little bottles aren't much cheaper to fill, and go fast.Lincoln 175HD
Reply:Too much filler bud, try a more heat and space your dips out farther. But atleast you've got the prices going well, also when you start getting into higher amperages your probably gonna wantSome more gas coverage. Other wise your on the right track, keep it melting.Miller bobcat 225g  - spoolmatic 1Mm250 - 30a spoolMiller spectrum 375Thermal arc 95 Everlast Ex 250As the boiler turns, these are the days of our lives
Reply:Originally Posted by slotardGet the biggest bottle you can. Little bottles aren't much cheaper to fill, and go fast.
Reply:Originally Posted by astaindsoul5446Too much filler bud, try a more heat and space your dips out farther. But atleast you've got the prices going well, also when you start getting into higher amperages your probably gonna wantSome more gas coverage. Other wise your on the right track, keep it melting.
Reply:I have started holding my torch at more of an angle and that has helped. I was holding it at almost 90 degrees. 75 or 80 seems easier.
Reply:On your Circle welds try starting at 12 O'Clock  and run to the left and the from 12 and to the right....keeping the puddle in front of the cup....These were pretty fast (Production welds)  so there is some filler that is left behind but if your slower and more careful you can make clean beads with no excess....Last edited by B_C; 10-25-2012 at 06:32 PM.  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Originally Posted by MechEngThanks, I have been trying higher current and the penetration is better. I find that, at least for now, using a large rod helps me as it cools things off as it is melted. I have been spacing the dips and the welds look a lot better. Consistency is a ways off though.I have been keeping the gas flow as low as possible to minimize my gas use with this tiny bottle.I have been trying some fillet and corner welds now. On these types the higher current is much easier for me to tolerate. I have also been trying some circumferential welds. Lots of black smoke and contaminated electrodes with the circ welds! My hands are not as steady as they once were.This is so cool.Rick