TA 185 balance / freq setting for aluminum

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using 3/32 lanthanated 1.5%1/8" aluminum flat sheetbalance adjustment range: 15-65frequency adjustment range: 15-150The recommended balance setting for my thermal arc 185 for aluminum is 20, but I've read others recommed using 60 for other welders.  I guess there is some difference as to what the number really means.  At 20 I think the area next to the bead looks to be cleaned, but if I increase to 65 then the cleaned area extends well beyond the bead.  I don't think I need it this far.  What is the advantage?  What should I use on 16 gauge tubing?For balance I found the higher the frequency the smaller the bead.  The guide for my unit shows 80hz for 1/8 and 100hz for 1/16.  I am only practicing now, but my first real work will be 16 gauge intercooler tubing.  I already have a bunch of 16 gauge tubing to practice with but so far I've only messed with the 1/8" sheet.  Is there a limit to what frequency I should be using?Thermal Arc 185TSW
Reply:chadr,sounds like you've got the balance effect on surface oxide cleaning figured out correctly.  The higher balance number is a greater percentage of DCEP in the AC wave which is removing surface oxides as electrons leave the base metal surface.  As you stated, you probably don't need the cleaned zone to extend out very far beyond the weld toe.  It probably doesn't hurt to have excess cleaning, but may be more of an aesthetic concern in applications requiring a good weld appearance/finish.I don't know the mechanism behind it, but the AC frequency affects the arc constriction, with a higher frequency creating a more concentrated arc.  This may be beneficial in making smaller width, more precise welds, and possibly increasing penetration for a given current.Maybe you could try a series of "identical" welds made with the same current, arc length, and travel speed, but at different frequencies, and show us the difference in the bead.
Reply:I have the same machine.  I found out a few things.  Welding some 3 x 3 x 1/4"  angle, I needed all she had.  I worked much better in the lower Hz zone, like 15 to 30.  Bead was wide enough, and penetration was good.  At the higher Hz, It just didn't seem to have the heat to make the welds.  I also bought a water cooled torch after that job.  Needed it, now I love it.For the cleaning, set it so the bead looks nice and no more.  I was welding some crappy aluminum tubing back together today. I cleaned it with a new aluminum grinding disk.  I had to turned the cleaning up to 65% to see how it would work.  I balled a 1/8"  2% thorated tungston.  I didn't think it would do that, but It did it twice and once with a orange cerated.  I turned cleaning down to 55% and it stopped balling.  I could watch the ball hang there getting ready to fall in the puddle.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:To David R,What water cooler do you use with your T/A 185?  Is the W/C torch a Thermal Arc brand?  May I ask a ballpark dollar figure for the water cooled set-up?  Sorry for the 3rd degree.Thanks, Flatliner.
Reply:I bought the cooler On Ebone.  Its from IOC, cost $544 buy it now plus another $54 for the torch cable cover.  Free shipping.  Its a vane pump.  Needs distilled water or Tig Cooler antifreeze, NOT automotive antifreeze.  So they say.  I love it.  Been using it a lot.  Just got a Cold Rolled Steel job.  If the guy likes my work and price, he has 22 more for me to do.  What timing.  For that job I will be using the TIG torch and cooler with my Invertec V350DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Thanks for the reply and good luck with the job.  You're sure to get the rest.
Reply:Originally Posted by pulserMaybe you could try a series of "identical" welds made with the same current, arc length, and travel speed, but at different frequencies, and show us the difference in the bead.