More aluminum welding questions

[LBHgti]

Sorry for all the questions....but I'm still having some trouble. The Machine is a TA185. It doesn't seem to matter how the machine is set up, what kind of tungsten I use, or what diameter filler rod. I'm trying to weld together (2) 1/8" 6061 coupons....the weld bead ends up being almost 3/4" wide and flat with very little (50%) penetration. If I reduce the heat, I get a narrower bead but less penetration. I've tried different torch and filler angles to no avail. At first I was using 1/16" 4043 rod, of which I used about 12" per 2" weld. Today I picked up some 1/8" filler, and a 3/32 pure tungsten. I'm using a #5 gas cup....What am I missing? I've got the machine set at 80 amps AC with the pulse feature turned off.

[LBHgti]

Made some progress....I cranked the amps up to about 140 and moved fast. I seem to be getting much better penetration (judged by the "can I bust it" test) and a much better looking bead. Am I on the right track?

[1990notch]

What kind and size of tungsten are you using? I seem to have best results with 2% ceriated. Use a pointed electrode with a slight flat on the end.

Can you post any pics of the welds?

Here's a couple links with some good info on settings, etc.:

www.millerwelds.com/pdf/gtawbook.pdf

www.millerwelds.com/education/TIGhandbook/

[greywynd]

Right, wrong, or otherwise, for 1/8" (which I'm welding a fair amount of) I set the amps to 150, pretty well floor it to get the puddle started, then back off as the material builds up heat. One of these days I'll have to get someone to watch the output display while I'm welding to let me know the actual current I'm running.

Mark

[LBHgti]

watch the output display while I'm welding to let me know the actual current I'm running.

Mark

Yeah...hehe....I tried to do that and ended up welding my torch to the table...It was good fun watching the evenings events through a confused HF auto darkening helmet...I can almost see straight again.

[vicegrip]

just a few weeks ago I had a pro do an aluminum encoder mount , I needed it to be right and pretty...

I was able to see through his oversized helmet past his undersized head....
the 1/8 tungsten was a ball , and it was so **** close to the metal , all the time , I would have stuck it several times.....and hangout was minnimal

the filler looked about .040" or so and was pushed into the puddle as soon as there was a puddle.....thinner filler than I would have thought...???

# 7 necked down cup (lense cup but fried screen in it ) and argon turned up some...
at one point the end of the cup came clean off leaving a # 7 size hole ...he never broke stride and loosened the stem and pushed the tungsten back , tightened it and kept right on welding , it was a 350 syncro DX I think... and it was hoovering around 225 amps most of the time ....I was glad to have him do it as my 350amp torch was loaned out , and I didn't want to overheat my 250..

this is the guy who does miricals to trashed boat screws (propellers)
I never question his practice on the A-stuff ,,,he was hired on a whim right out of H.school to salvage aluminum chrysler intake manifolds that were cast with flaws ...