Tig set up help please......

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Looking for opinions on setting up my Tig to weld aluminium (sp?), machine is 200 amp ac/dc inverter, I have 0.8% Zirc (white tip) tungstens and 2.0 % Thor (red tip) tungstens at the moment but don't mind buying different, there is no foot pedal on the machine now but I will be adding one when funds permit.Alloy is 3003 in 0.63" thickness (for a fuel tank), I have plenty of offcuts to practice on I'm quite happy welding mild steel and 4130 but have no experience with alloy's,appreciate any tips!Thanks.
Reply:if you dont have a pedal, I suppose you must scratch start?and seing as how aluminum seems to build up a lot of heat as you weld.... you normally need to taper the current down quite a lot from what you use to start the bead...i think having no pedal (or hand amp controll) will be very very frustrating.  -far far more so than steel would be.
Reply:I'm going to guess a typo at 0.63" or almost 5/8" thick.  I'm guessing .063" maybe? If not what sort of fuel tank are you building with 5/8" alum?Alum this thin to start leaning to tig alum will be a challenge to say the least. I would recommend seeing you doctor for blood pressure meds and tranquilizers before trying to start.Try and start with 1/8" alum to get a feel for what to expect. As said with out a pedal this will be challenging to adjust the heat. You know you should have the machine set for AC tig, yes? On 1/8" alum 3/32 tungsten (I use orange or gold), 125-160 amps depending on your joint, 100% argon, 3/32 filler or 1/16" filler. Cleaning will be important the alum oxide will melt at a much higher temp than raw alum.On 1/16" alum 1/16" or 3/32" Amps at 70-90 1/16" filler.Hope this helps.
Reply:"I'm going to guess a typo at 0.63" or almost 5/8" thick.  I'm guessing .063" maybe? "Oops! yes my mistake, it is .063.Thanks for the advice so far. I read on a previous post (can't remember who) somebody said with an inverter you can use red tip tungstens on alloy and use them sharpened to a point as per steel use, any advice on that?Thanks.
Reply:Oh boy, here we go....There are a lot of opinions on which tungsten is "best" for alum. I have heard red, orange, gold, frequently suggested. as well as the old green pure tungstens. For an inverter you do point the tungsten. Honestly at this point I doubt that the red will really matter all that much. You will be practicing for quite a while most likely. So I would start out with what you have. Personally I run orange for almost everything including alum. You are not building a plane for Boeing so I would not worry about some slight contamination of the weld by the tungsten at this time.Just go out and try and run some alum and all this will begin to make some sense. Almost everyone that I know who decided to try alum had an eye opening exp. when they realized it welds nothing like they were used to on steel.Good luck and keep us posted.
Reply:ACHF, Argon  and Green (Pure).   JohnSMAW,GMAW,FCAW,GTAW,SAW,PAC/PAW/OFCand Shielding Gases.  There all here. :
Reply:So what is the tank for? The last time I answered a question like this, I found out the guy was building fuel tanks for his homebuilt airplane! IIRC he used .040. Unless you're making a motorcycle or some other smallish tank, .063 is pretty thin. I also agree with others, you're in for a rude awakening. Alum is hard to weld and .063 without a pedal.....whew............I'm not trying to be an a$$, just a hobby guy that can 'sorta' weld alum. Red or green or orange or blue tung, whatever, doesn't matter. It's the person and AC, not the tungsten.Learn with 1/8 alum stock, 3/32 tung and 3/32 filler.My tip: lay a backing piece behind all of your welds, to keep the alum puddle from falling out. It will also dissipate heat. You will learn a lot faster than I did, no internet to ask when I taught myself. You really need a pedal. Last edited by Craig in Denver; 06-05-2008 at 05:05 PM.9-11-2001......We Will Never ForgetRetired desk jockey. Hobby weldor with a little training. Craftsman O/A---Flat, Vert, Ovhd, Horz. Miller Syncrowave 250
Reply:Once again DO NOT USE PURE TUNGSTEN ON AN INVERTER MACHINE...T.J.www.tjsperformance.comDynasty 300 DXHTP 240HTP Microcut 380Hyperthem 85JD2 Hyd Bender and HF Hyd Ring Roller all in one =(Frankenbender)Bpt. Mill/DRO4' x 8' CNC Plasma TableInstagram: tjsperformanceYT: TJS Welding and Fabrication
Reply:TJS: Good point.Note to self: I have a transformer machine, many questions are asked by those with inverter machines. This thread, for instance.I'm just curious, what happens when a pure tungsten (green) is used in an inverter? Does it melt and drip into the puddle, does it fracture or split? Does it 'wear down' rapidly?  Since my Syncro 250 will outlive me; it's here to stay.Thanks, Craig Last edited by Craig in Denver; 06-06-2008 at 03:47 PM.9-11-2001......We Will Never ForgetRetired desk jockey. Hobby weldor with a little training. Craftsman O/A---Flat, Vert, Ovhd, Horz. Miller Syncrowave 250
Reply:Originally Posted by TJSOnce again DO NOT USE PURE TUNGSTEN ON AN INVERTER MACHINE...T.J.