Out of my element in aluminum...

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...and no one else in the company can assist me.Since October, it appears as if I have been designated as the test/qualifier, guinea pig, for our company to become certified/qualified in 2G and 3G for the latest ISO's out there for Gov't contracts using the GMAW app.I've tested on all sorts of steel alloys from 8" long coupons to 30" long coupons, anywhere from 1/2" to 1", that get x-rayed then, they go through the tensile tests.Lemme tell ya, 30" is a long way welding uphill.With all of that complete, this week I begin the aluminum process - something I've never welded out of position - and I am required to use 3/64" ER5356 aluminum wire on 1/4" plate, set up for 3G with a 1/4" open root with a 1/4" backing plate of aluminum.Eventually the 2G will come along as well.The testing lab tells me that I cannot use my usual weave pass as I would on steel, and have to drag it straight up at a minimum of 180 amps and 25 volts - maximum of 225 amps and 27 volts.The ancient Miller machine I am using has a wire speed control inside the feeder, outside of the feeder on the front, and on the gun itself that contols the previous two controls.I was able to get the parameters required, but I'll be danged if I can get the first two tie-in roots in the open face to look like something that you'd want to call a root.Does anyone know anything about the technique I should be using, or any vertical up technique on aluminum, as these 1/4" coupons have to pass x-ray and tensile?
Reply:I think that I forgot to mention that these tests are all butt joints.Last edited by soeastbiker; 03-08-2009 at 02:24 PM.