Welding Aluminum bead question

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HelloJust got a Hobart 210 with a 100 spool gun. I am trying to build an aluminum truck bed as my first aluminum project.I am pretty sure my welds are penetrating ok but the bead is not very flat, looks ok? but is is humped up not sure if it should be? I am welding 3/16 channel I have tried settings 5,6and 7 100% argon with a flow of 25. I am holding the gun tip about 3/4" away from work and tilted slightly back (as described in manual)In side corners look really great but the outside corners and flat humps upAny advise???ThanksDavid
Reply:Can you post a pic? Hard to say with out seeing what the weld looks like. Have you done a test, brake, bend and or etch test to make sure you are getting the penetration you need. Is the aluminum warm, cold, what is the humidity like where you are welding inside or outside? Is the weld coming out shiny or dull and smoky? Aluminum welds should be relatively flat not too humped up. If it's humping up it might be to cold and to slow. A pic would help.Cheers
Reply:Agreed picts would help, so would all the info, like wire size and type and speed. Also how are you prepping the joints? I see a lot of guys who like to make outside corners but joints rather than V joints. Those welds almost always look more "humped" as there is no where for the weld material to go. Alum welds different than steel. I'd start with that machine on the highest voltage setting and start with the wire speed almost at max and then start working my way down. My guess is you'll probably end up maybe 1 tap down from max and the wire speed you need will depend on the wire size. For .030 wire, I'd bet you are close to 85-90 on the wire speed. You also will want to push the weld and go pretty quick. 3/4" sounds a bit far to me, I'd probably be closer to 1/2" myself, but it has been quite a while since I ran my spoolgun on alum this thickness since I got my tig..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:Thanks for the replies. I will get you some pics to see. Thanks againDavid
Reply:Having trouble with pics. However I Tried the advise given, Running 035 wire welder set on 6 and 95 and got closer. What a difference beautiful beads. This hobby is enjoyable when things work right. Thank for all the advise!Just one problem the outside corners still look like crap. Bird poop and sometimes goes thru set on 6ThanksDavid
Reply:Bird poop on an outside corner might mean you are loosing gas shielding. Issue might be due to too much gas flow as you might be sucking air in to the bead. Again hard to say with no picts.Burn thru is tough on outside corners, since if you set it up like a V you have a very thin center. You'll have to play a bit with settings, travel speed etc to try and find the sweet spot. Again picts would help.What issues are you having with picts? Maybe someone here can guide you thru 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