aluminum tig contamination

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okay so i posted before i am having a real big issue with contamination  in m aluminum tig welding. im using a 3/32 2%ceriated tungsten about anywhere from 13 to about 18 cfm on the argon flow. a #7 cup using 4043  tried 3/32 filler rod. i hand wire brushed the aluminum with a SS brush. set my machine at about 140A with a foot pedal ac balance is 90% cleaning action and about 100hz on the high frequency.  it looks clean then it starts to melt and just gets a ton of black **** in it. what the heck am i doing wrong!?miller bobcat 250 ntsouth bend metal latheClausing verticle millrikon 17" bandsaweverlast 250exharris oxyfuel set upspeedglass AD helmet with adflo power respirator.
Reply:pictures........what type of aluminum?  Cast or billet?  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Check your gas flow too. It could be your gas is surging out at the start, then petering out just as the puddle starts melting.Same thing was happening to a customer of mine. He would tack alum assys for me to do the finish weld. The tacks were really crusty and he said he could start the arc, barely get a tack before it crusted up on him. I ended up going over to find that the end of the backcap was broken off and he had the gas flow at 50cfh.Last edited by shovelon; 08-23-2011 at 01:57 PM.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:Welder needs to be plugged into a Chinese power grid.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Originally Posted by SundownIIIWelder needs to be plugged into a Chinese power grid.
Reply:Continual comments like SundownIII's simply push people away from this site , which I always thought was about welding . It's really a shame . Pretty soon , people will be reluctant about even asking a question for fear of being flamed for what brand of gear they use . This will defeat the purpose of this site entirely ( or at least what I thought it was about ) . Learning .Miller MM252 with Q300Hypertherm PM1000Everlast Powertig 200DXMiller Syncrowave 200
Reply:its just some scrap billet aluminum ill get pics asap. and as for you sundown say what yah want about the machine its not the best sorry i cant afford to buy a miller. but to bad for your comment  that i am having this problem on a miller machine at school. i havent had a problem like this with my everlast miller bobcat 250 ntsouth bend metal latheClausing verticle millrikon 17" bandsaweverlast 250exharris oxyfuel set upspeedglass AD helmet with adflo power respirator.
Reply:Got Cha Jay........LMAO  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Originally Posted by firedup198its just some scrap billet aluminum ill get pics asap. and as for you sundown say what yah want about the machine its not the best sorry i cant afford to buy a miller. but to bad for your comment  that i am having this problem on a miller machine at school. i havent had a problem like this with my everlast
Reply:"Welder needs to be plugged into a Chinese power grid."Good God man don't do that......it'll start shooting rice and lightly cooked Schnauzer bits out the cup
Reply:Good lord here we go again..By the way its Neverlast..Commie power grid.....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:thanks for the help from you guys that had something useful to say. all the other guys who seem to know nothing but how to rip on other peoples machines please use this thread to continue your bs and stop wasting the time of people on other threads here trying to get some helpmiller bobcat 250 ntsouth bend metal latheClausing verticle millrikon 17" bandsaweverlast 250exharris oxyfuel set upspeedglass AD helmet with adflo power respirator.
Reply:Does anyone else wonder why if the school welder is not performing properly, he feels it necessary to ask the question of an internet board, rather than the INSTRUCTOR?It's probably turning black because you're stirring the puddle with your tungsten.Did you ever consider that maybe we at times get a little short with people because of all the dumb azz questions the guys with their new chinese POS welders ask.  Maybe if they included a usable owner's manual with those machines (and the buyers would read them) we'd all be better off.  Oh yeah, if they did that, then they'd have to charge almost as much as the big guys do.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Did it ever occur to you that perhaps the OP asked the question here because he values the opinion of certain contributors as much as , if not more so than his instructor ?Not all instructors are created equal and there are people here , like you SundownIII and Zapster that have obvious skill , experience and expertise that have a lot to offer to everyone , especially someone that is just learning the nuances of the trade . Everyone had to start somewhere , even you guys . Perhaps you've forgotten that .Instead of taking the opportunity to be a leader , mentor and hero that EVERYONE on this board would look at and say "Wow , that dude really knows his stuff and is willing to help out a fellow tradesman" , your focus instantly is directed at what brand of gear the guy owns . Quickly followed by your insults and negativity .What a shame . Step, up to the bar guys , be leaders , and leave the BS opinions and negativity concerning brand names in the shadows . Not everyone has the financial resources to own whatever they want . If you find  questions stupid and frustrating , simply don't respond . This board can be a terrific venue to learn and it's high time that things get back on track before good people simply get fed up and go elsewhere .Miller MM252 with Q300Hypertherm PM1000Everlast Powertig 200DXMiller Syncrowave 200
Reply:Tigster,Have you ever considered that there seems to be a direct correlation between a welder's selection of a welding machine and how committed he/she is to learning how to use it correctly.Notice here that I didn't say cost.  Cost has nothing to do with it.  As a prime example, I'll use Zap.  Here we have a guy using a machine with technology developed over 30 years ago.  He'll still outperform 99.44% of the guys using the latest technology with all the bells and whistles.  You know why.  Because he applied HIMSELF to developing those skills.Most of us "old timers" learned to weld long before the advent of the internet and message boards.  We read books, took courses, listed to the old guys, melted a lot of metal, and took our lumps when we asked the "old guys" dumb questions.Now, with the information age, we seem to have a new generation of welders who think all they need to do is buy the latest technology (with all the bells and whistles), turn that sucka on and join a message board to be spoon fed the answers they could have learned themselves with just a little study or hood time.So many of the questions asked are pure BS that shows the OP has put forth NO EFFORT on their own part.  Combine that with not providing enough information so that the experienced guys can provide guidance, and you have a cluster in the making.  Then you have the likewise uninformed posters jumping in with their BS responses.  Finally, one of the knowledgeable posters finally jumps in to "clean up the mess".  In so doing he has to point out the misdirected guidance that's already been posted.Gaining knowledge is a two way street.  Show the experienced guy you've put forth an effort and he'll bend over backwards to help.  Show the experienced guy you're lazy and haven't put forth any effort and he may well reply in a not so polite fashion.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:as an Ol'Timer (also Well Said,...  Sundownidealarc 250/250 ac-dc tigidealarc 250/250 ac-dc tig #2 used for sticklincoln sp100hh125dual arbor grinder polisher30 yrs of hand tools52 pitch blocks 6p-26prake gauge -pitch gaugeG&D prop repair 918-207-6938Hulbert,okla 74441
Reply:Sundown , I appreciate what your saying , but , you are making a huge assumption as to what kind of effort this OP has really made to learning . You really have no idea how much effort this guy has made . You are now condeming him because he is asking a question on a forum . A forum that you yourself are a member . If the forums have no value and if you are going to condem people for using them as a learning tool , why are you here ? Is this a forum for "old timers" to hang out and bitch about "the good old days" that are now gone ?No , of course not . It's a modern mechanism for all of us to share our passion for welding and for some of us to hopefully share our wisdom and experience for the benefit of others . That's the value of modern communication . I can learn more from you , in a shorter period of time .Is it a substitute for melting metal ? No , of course not . It never will be . But , you just mentioned that at one time , you had to ask "old timers" questions too . In those days forums did not exist , but I'll bet $100 , that if they did , you would have used them too . Why wouldn't you ? It's all about learning and seeking out the best people to learn the most from . That's just smart .I completely fail to see the correlation between the a buyer's selection of a welding machine and his "apparent" commitement to learning how to use it . Are you suggesting that a person that is learning to weld is more "commited" to learning if he buys a 30 year old machine ? That makes no sense whatsoever .A modern inverter is able to do things technically , that the older generation of machines simply weren't capable of . Period . Is it a substitute for learning the right way ? No , of course not . No one ever said that it was . People buy Dynasty's for a reason . They have capabilities that Syncrowaves don't . I'd love to own one .Don't get me wrong , there are ridiculous people asking repetitivly stupid questions . But please don't lump all new welders into this catagory . Try not to forget that at one time , you likely asked some pretty stupid questions too . It's called learning . We've all been there . If it pisses you off , don't get involved . Simple as that .As I've said before , in my opinion , some of you guys have an incredible amount of knowledge . This knowledge has tremendous value . I will never appologize for seeking out people with knowledge and asking questions . All I ask in return is that the people with knowledge , keep an open mind and stay focused on the point .Miller , Lincoln , ESAB , T/A , Everlast . Who gives a **** ?  Lets f***king weld and move on man .Miller MM252 with Q300Hypertherm PM1000Everlast Powertig 200DXMiller Syncrowave 200
Reply:Originally Posted by SundownIIITigster,Have you ever considered that there seems to be a direct correlation between a welder's selection of a welding machine and how committed he/she is to learning how to use it correctly.Notice here that I didn't say cost.  Cost has nothing to do with it.  As a prime example, I'll use Zap.  Here we have a guy using a machine with technology developed over 30 years ago.  He'll still outperform 99.44% of the guys using the latest technology with all the bells and whistles.  You know why.  Because he applied HIMSELF to developing those skills.Most of us "old timers" learned to weld long before the advent of the internet and message boards.  We read books, took courses, listed to the old guys, melted a lot of metal, and took our lumps when we asked the "old guys" dumb questions.Now, with the information age, we seem to have a new generation of welders who think all they need to do is buy the latest technology (with all the bells and whistles), turn that sucka on and join a message board to be spoon fed the answers they could have learned themselves with just a little study or hood time.So many of the questions asked are pure BS that shows the OP has put forth NO EFFORT on their own part.  Combine that with not providing enough information so that the experienced guys can provide guidance, and you have a cluster in the making.  Then you have the likewise uninformed posters jumping in with their BS responses.  Finally, one of the knowledgeable posters finally jumps in to "clean up the mess".  In so doing he has to point out the misdirected guidance that's already been posted.Gaining knowledge is a two way street.  Show the experienced guy you've put forth an effort and he'll bend over backwards to help.  Show the experienced guy you're lazy and haven't put forth any effort and he may well reply in a not so polite fashion.
Reply:sorry i dont know what im doing wrong guys i do read about how to do this stuff i research a lot of information i paid for schooling to learn a good trade and bought a machine i could afford at this time so i could spend extra hours practicing my welding because we all know the best way to learn is by doing and making mistakes. unfortunately i couldn't figure out what i was doing wrong so i figured i'd ask. yes i understand a lot of people come on here to get spoon fed and im not looking to be that person but if i have to ask a question to be a better welder ill ask it. as for taking lumps for asking stupid questions give me whatever you have but give me a helpful answer too if you don't mind. im here because no person looks at a problem the same way so the more answers you get the more you can try to learn what works and what doesn't. i am trying to learn what i consider an art but a book cant know all the answers.miller bobcat 250 ntsouth bend metal latheClausing verticle millrikon 17" bandsaweverlast 250exharris oxyfuel set upspeedglass AD helmet with adflo power respirator.
Reply:I think there is some benefit to learning on a older machine without all the bells and whistles...  it makes us focus more on technique and prevents us from screwing up by using the wrong settings.    Zap is a prfect example.   His tig of choice is an s wave machine without ac balance, up/down slope settings etc.    Yet his welds are awesome.   Being I have basicly the same machine  its a great reference fo me to see where operator error/skill causes differences in the weld result.   Having taught high school shop class I can tell you all that new weldors often don't understand what practice time entails.  Its not 20 mins or a couple of hours.  Its hundreds of hours under the hood developing those skills.     As I only weld for a hobby, when I start a project I usually spend half hour just practicing on the type of material an process I am going to use.  Esp if its tig or stick or a material I don't use often.    For example I don't do much sheet metal so when if I am working on such a project I expect to spend a fair amount of time running beads in various positions to dial in the machine and my technique for that application even though I have been welding as a hobby for 20+ yrLast edited by soutthpaw; 08-25-2011 at 01:19 AM.Tiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:Originally Posted by firedup198okay so i posted before i am having a real big issue with contamination  in m aluminum tig welding. im using a 3/32 2%ceriated tungsten about anywhere from 13 to about 18 cfm on the argon flow. a #7 cup using 4043  tried 3/32 filler rod. i hand wire brushed the aluminum with a SS brush. set my machine at about 140A with a foot pedal ac balance is 90% cleaning action and about 100hz on the high frequency.  it looks clean then it starts to melt and just gets a ton of black **** in it. what the heck am i doing wrong!?
Reply:sundown well said to the OP where are you locatedMiller Xmt 350Lincoln Ln-25Ahp 200xSmith Gas Mixer AR/HTig is my Kung FuThrowing down dimes and weaving aboutInstagram http://instagram.com/[email protected]
Reply:im in ocean county nj and the tank pressure is at 2000 psi.miller bobcat 250 ntsouth bend metal latheClausing verticle millrikon 17" bandsaweverlast 250exharris oxyfuel set upspeedglass AD helmet with adflo power respirator.
Reply:Originally Posted by zapsterOh my..I never thought this would happen..If I ever get down your way I WILL buy you a couple of  and we will chat about the good 'ol dayzzze..And FWIW I will offer help here to ANYONE with ANYTHING!Just ask my friends..(All 3 of them)..I actually like helping out anyone no matter how it seems sometimes.....zap!
Reply:Originally Posted by B_CHey ZAP  can you help me pick the apples off my two trees, my Springers are eating them as they fall on the ground and getting the "Squirts"a parachute upside down on treeidealarc 250/250 ac-dc tigidealarc 250/250 ac-dc tig #2 used for sticklincoln sp100hh125dual arbor grinder polisher30 yrs of hand tools52 pitch blocks 6p-26prake gauge -pitch gaugeG&D prop repair 918-207-6938Hulbert,okla 74441
Reply:Originally Posted by soutthpawI think there is some benefit to learning on a older machine without all the bells and whistles...  it makes us focus more on technique and prevents us from screwing up by using the wrong settings.    Zap is a prfect example.   His tig of choice is an s wave machine without ac balance, up/down slope settings etc.    Yet his welds are awesome.   Being I have basicly the same machine  its a great reference fo me to see where operator error/skill causes differences in the weld result.   Having taught high school shop class I can tell you all that new weldors often don't understand what practice time entails.  Its not 20 mins or a couple of hours.  Its hundreds of hours under the hood developing those skills.     As I only weld for a hobby, when I start a project I usually spend half hour just practicing on the type of material an process I am going to use.  Esp if its tig or stick or a material I don't use often.    For example I don't do much sheet metal so when if I am working on such a project I expect to spend a fair amount of time running beads in various positions to dial in the machine and my technique for that application even though I have been welding as a hobby for 20+ yr