View Full Version : corner welding aluminum
11-06-2008, 08:44 PM
Hey im new to the whole tig welder realm but i have welded aluminum with a spool gun for a few years not that that helps that mutch. any how im trying to weld 1/8 plate together on the corners but i am having trouble getting the 2 pices to create a single puddle. once i do get a single puddle i can make a bead that is ok fo just starting. my welder is a syncrowave 250 dx 3/32 tungsten and using argon only. voltage at 110 ish and the wave is balanced or a bit to the penetrate side any help would be great. thanks
11-06-2008, 09:09 PM
Inside corner joint or outside corner joint.
Outside is easy if you just dab a little wire to get started then get busy adding wire and welding. Tack often to keep the joint correct.
If you want to weld an outside corner joint autogenous, it's a bit harder. I just gag the tungsten a tiny bit into the puddle and it flows together very easily. I know that I will catch some flack for advocating the gaging of tungsten on purpose but if you do it right, you wont hurt the tungsten or the weld.
Inside corner joints are tough if you aren't experienced at it. Start away from an inside corner and run in towards it.
Ten different welders will tell you ten different ways to do the same thing.
11-06-2008, 09:35 PM
yah it is the outside corner but my problem is tacking it together without wire. im new so can you tell me what gaging is? thanks
11-06-2008, 09:45 PM
Gagging the tungsten = touching the puddle. If you do it ever so gently, you can get by without hurting the weld.
I spail reel bad. Meant to say gagging.
11-07-2008, 01:21 PM
I find it easier to start a bit away from the corner - maybe 1/2" oor so, then once a bead is somewhat esablished run it to the corner and start the final weld.
As mentioned, everyone is different. I weld a lot of 1/8 AL tubing in any number of joint configurations with a 250DX. I usually run 1/8" tungsten, 100% argon, 20-25 CFH, #7 cup at around 120-140 amps. I usually set the output max to around 190A then moderate with the pedal. I floor it to get started then back of as the welding starts.
It might help you to sand/grind a small flat on the outside corner - this way you will have the ability to add filler without so much build.
11-10-2008, 08:58 PM
I do the Pangea way and sometimes it will just fuse without touching also...the techique is aquired and worth learning.:cool:
I probably should have read ALL the replies before jumping in here...BUT...As soon as I saw your settings I figured that I would at least talk about that. Unless you are production welding (same part after part) Setting the machine to be FLOORED
probably won't be a good idea...Why you ask? Because aluminum soaks up heat really fast, and you will need that little extra ( Pedal) to get through CORNERS. I hardly ever set my machine with less than 130 amps on 1/8 aluminum....So that is something you can try right away....What Pangea said
about different styles of welding a corner is pretty close to what everyone that weld aluminum will do... Just remember.....You need the extra amps to get through a corner or you will spend too much time and over heat the area.
Don't be afraid to run that rod in there with some Horse power behind it.
11-18-2008, 11:48 PM
BC, Nice looking welds as usual.
Attached are some welds that I made on a fixture used to test the Hard stops on a robot for work. It includes outside and inside fillet welds. The metal thickness was about .080 inch thick. (Not quite the 1/8" you are working on.) I did use filler rod on all welds.
Cool that extruded
piece on the sides looks pretty tough...Welds look OK ....Top weld looks a little
cold but maybe just a little too much filler rod, which is just opposite of what most guys do (afraid to push the filler in ) So that's not a bad thing. Don't be afraid to use some HP on aluminum. I teach my guys to watch the puddle on the Parent metal and never let it deplete.... Looks good and strong...I think I would have wrapped the corners...
11-20-2008, 08:08 PM
I looked carefully at my corner welds and I agree with your assessment. Thanks for your comments.
Typically speaking I think most engineers and good fabricators like seeing a WRAPPED corner weld....Makes for a stronger joint and assures that a Crack won't start from an unfinished weld.....I just like the way it looks over all..