Al. tig questions (where's Zap?)

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OK, I searched and I searched, and didn't quite fine the answers I'm looking for, though I did look through nearly all Zap's threads involving aluminum.Finaly picking up a Tig machine with AC (TA-185 ) so it's time to play with aluminum. My first question is about sheilding gas, I have a tank of pure Argon, and a tank of mig mix (75ar/25co) and a 3rd empty cylinder that I can exchange for a full cylinder of whatever gas I feel like. Can I use pure Argon for aluminum with decent results, I noticed Zap uses a lot of mixed gas, mainly Argon and a little Helium, so should I pick up some Helium, why would I need that? I've heard pure Helium gived great penetration, but since I plan on doing 16-11ga I don't think penetration is going to be a major problem. Idealy I want to have as few different gasses on hand so that I can keep a couple bottles of each handy for when I run out on Sunday.Also I have a huge quantity of Al. sheet laying around the garage that I go for free, but have no idea what alloy it is, my guess is a 50xx series, but who knows. Can I use 4043 filler with 5053 sheet, I noticed Zap used 5053 with 6061 plate to repair a cast peice, so I assume it works, but do certain alloys no mix? I'm not looking for X-ray quality work, just some custom brackets and storage boxes for now, and then probably valv-covers, dashes, and air-boxes down the road.Thanks ahead of time for the help.
Reply:You use Ar or He ONLY, no CO2 or any other gases.  He is only needed for heavy materials, or to get by on a material whose thickness is marginal for the amperage output of your machine.  If 1/8" is about the heaviest you will go, you do NOT need ANY helium, by any stretch of the imagination.
Reply:The only grades of aluminum you can't readily weld is 7000 series. And Supe is right. Straight argon for most of the welding. As for filler between grades, 4043 is fine, or 5356. Many use 5356 for higher strength welds, and for stuff that will get anodized. 4043 is the standard' any old filler will do' aluminum- good working properties.And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:I have the TA-185, you'r gonna love it!  I can weld up to 1/4" with pure argon.I did end up getting a water cooled torch.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:You will get more consistent results hand welding with Argon.  Helium will change the power more if your arc length changes, and is better suited to automatic welding.  Helium does give more penetration at the same power setting, but for thin gage it does not matter much.
Reply:Cool, looks like I'll just get my spare cylinder re-filled with Argon, I rarely need a spare bottle for the mig, stuff lasts forever.What about filler, I beleive most alloys can be welded together, but is there one alloy of filer that does a better job, or is more versitile? Originally Posted by David RI did end up getting a water cooled torch.
Reply:75%Agron/25%Helium is also a good mix, if you think you will be doing some 1/4" on occasion.  It's not enough helium to really give any arc wandering or starting problems.
Reply:I run around 38% argon..Gas mix = 40 amps or so VS. straight argon..What I'm trying to type is that with a mix you can cut you amps by 40 and get the same results than with +40 amps using straight argon.. ...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:Zap, are you kidding or who mixes 38% argon for you.  I thought I was the only one who trys different mixtures, that are not a standard.    JohnLast edited by weldgault; 12-19-2007 at 03:44 PM.SMAW,GMAW,FCAW,GTAW,SAW,PAC/PAW/OFCand Shielding Gases.  There all here. :
Reply:Zap has a nice little gas mixer. It has a few quirks but I am still jealous. I'd like a similar setup for my 200DX.Jim
Reply:Originally Posted by weldgaultZap, are you kidding or who mixes 38% argon for you.  I thought I was the only one who trys different mixtures, that are not a standard.    John
Reply:Originally Posted by zapsterI run around 38% argon..Gas mix = 40 amps or so VS. straight argon..What I'm trying to type is that with a mix you can cut you amps by 40 and get the same results than with +40 amps using straight argon.. ...zap!
Reply:Okay, just got back from the welding shop with 1lb of 4043, and 1lb or 5356, see which one I like better, now I just have to wait for UPS for drop off the machine, should be here next tuesday, but freaking Christmas gets in the way and I won't have it untill Wednesday.
Reply:That is true, but the additional helium probably costs more than the extra electricity would. That's why I usually only reccomend using as much helium as you NEED, based on the limitations of the machine's output.
Reply:I understand and agree.  It's nice at times, when you don't have to buy the supplies you use each day.
Reply:Yes ole Zapster has a nice mixer.....jealous weld it like you own it
Reply:Straight argon. Argon gas is used to prevent arc wandering as well as keeping oxygen away from the weld pool.Helium is used on heavy sections because it increases the penetration.4043 is a general purpose filler wire .5356 is for corrosin resistance, with 5356 alloy for marine use.It has other uses as well.Last edited by Donald Branscom; 12-23-2007 at 02:20 AM.