Please critique my welding [pics of turbo project]

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So I received my welder about 2 weeks ago and I've been putting in a good amount of hours on some days.I really wanted to learn aluminum so I decided to jump right in.I've never taken any welding courses but have tried to pick up as much as possible. After receiving the welder and putting in so many hours and having my whole body ache, I have a new respect for quality welders and I would greatly appreciate some advice and feedback.The project car:The welder:Thermadyne Arc Master 185 inverter tig.Pic 1,2,3: Compressor housing is cast aluminum about 1/8 thick...maybe a tad thicker. [110 max amps, 80, frequency, 50 wavelength, 1/16 2% thoriated electrode, 1/16 filler rod] I didn't have any 3/32 electrodes nor filler so I just used 1/16. I found my electrodes were balling up at the tip.Pic 4,5,6: 1.6mm Aluminum pipe [ 50 max amps, 110 frequency, 50 wavelength, 1/16 2% thoriated, 1/16 filler rod]Pic 7 (different pipe): 1.6mm Aluminum pipe [ 50 max amps, 110 frequency, 50 wavelength, 1/16 2% thoriated, 1/16 filler rod]
Reply:For never taking a welding class- I think you did a fine job over all, looks like a pretty cool project to boot !Dan.Repair Specialties LLC
Reply:Originally Posted by DanMFor never taking a welding class- I think you did a fine job over all, looks like a pretty cool project to boot !
Reply:Looks really good for not having taken any classes or formal instruction, especially on aluminum. That stuff can be tricky when your learning.I'd say that you have the basics down but just need a little practice to get the consistency. Learning when to dip the filler and how much to dip will get your beads to be consistent.I can't tell what exactly the little spots on pic #4 are. Maybe some crap from the inside of the tube that came through when you were welding or maybe something that got on it after the welding? Everything else looks nice and clean except that spot. Cleaning with aluminum is critical.You might want to try some 3/32" tungsten. The tungsten is supposed to ball up at the end when welding on AC but the thicker diameter will handle more amperage when welding thicker materials.Give yourself a little more seat time and your welds will go from good to great.- Paulhttp://all-a-cart.comWelding Cart Kits and accessories
Reply:Originally Posted by ZTFabLooks really good for not having taken any classes or formal instruction, especially on aluminum. That stuff can be tricky when your learning.I'd say that you have the basics down but just need a little practice to get the consistency. Learning when to dip the filler and how much to dip will get your beads to be consistent.I can't tell what exactly the little spots on pic #4 are. Maybe some crap from the inside of the tube that came through when you were welding or maybe something that got on it after the welding? Everything else looks nice and clean except that spot. Cleaning with aluminum is critical.You might want to try some 3/32" tungsten. The tungsten is supposed to ball up at the end when welding on AC but the thicker diameter will handle more amperage when welding thicker materials.Give yourself a little more seat time and your welds will go from good to great.- Paul
Reply:Very good for a start.  Looks like you need more amperage on some of those welds, pics #4, 5, 6 (or preheat, but that's a pain in butt weld).  The estimated amperage capacity of 1/16" electrode with AC is about 80 to 100 amps.  A 3/32" should increase the limit to about 130 to 160 amps.See Diamond Ground Products guide.http://www.diamondground.com/Guidebook0105.pdfInverters with frequency adjustment can run the proper size tungsten electrode with a tapered prep. and blunted tip, without balling up.  The old xfmrs ball the tungsten.If you're not sure how much penetration you are getting, then the strength provided by the weld filler build-up will help.
Reply:Originally Posted by pulserVery good for a start.  Looks like you need more amperage on some of those welds, pics #4, 5, 6 (or preheat, but that's a pain in butt weld).  The estimated amperage capacity of 1/16" electrode with AC is about 80 to 100 amps.  A 3/32" should increase the limit to about 130 to 160 amps.See Diamond Ground Products guide.http://www.diamondground.com/Guidebook0105.pdfInverters with frequency adjustment can run the proper size tungsten electrode with a tapered prep. and blunted tip, without balling up.  The old xfmrs ball the tungsten.If you're not sure how much penetration you are getting, then the strength provided by the weld filler build-up will help.
Reply:Man, talk about jumping in with both feet!  Even did the cast housing.  Im impressed.  Im new at this too, but Im still farting around with coupons and such.  GJ.Various GrindersVictor Journeyman torch200cf Acet. 250cf oxygenLincoln 175 plus/alpha2 gunLincoln v205t tigLincoln 350mpEsab 650 plasmaWhen you can get up in the morning, Its a good day.Live each day like its your last.
Reply:Your a natural..And as you stated you picked up stuff here.. practice and a little more practice is all thats needed..is that a Mass. Inspection sticker on the windshield??...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:Looks great so far. What car is that? There is a place called "New Era Performance" near me and located in Rochester.John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Originally Posted by DoolittleMan, talk about jumping in with both feet!  Even did the cast housing.  Im impressed.  Im new at this too, but Im still farting around with coupons and such.  GJ.
Reply:Very nice, I've done a few turbo cars. John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Where in mass are you?I am too.....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:Originally Posted by zapsterWhere in mass are you?I am too.....zap!
Reply:Whatcha doing sat am?Tig class free.....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:I may have to come to this one and learn a thing or three. How long are you guys planning? I need to plan to have a sitter or grandma watch my son.John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:9 A.M. Untill its worth it for everyone.. ...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:Originally Posted by zapsterWhatcha doing sat am?Tig class free.....zap!
Reply:Originally Posted by UnderwhereNoo!!!I'm going to NYC on friday night and coming back Saturday.What do you mean by TIG class? Where? What equipment?i'd love to have someone show me the ropes a bit. Very open to learning.
Reply:Originally Posted by zapsterI go over the basics..and everyone gets "seat time"It wont be the last one..so dont worry..Heres where we do it..www.monarchmachineworks.comHobart AR250-HF tig machinewatercooled torch..I'll be in touch.....zap!