aluninum basic settings

[Wecf]

Hi everyone,
I have figured out my settings for steel. Now I'm trying to do Alu. My first attempt did nothing, it just formed an arc but never got a puddle going. My 2nd try just melted my 2% thoriated tungsten. So assuming that I know nothing (not far off reality LOL) what should my welder setup be? I have a 256pi. Please include amps, argon rate, torch/ground polarity, 2/4f? HF? Thanks

[SICFabrications]

lol.... since no one else will offer any advice, i will go over some settings with you.... first things first, you really need to research the forums on my other posts regarding aluminum... i will post a few links for ya... you should use tri-mix or rare earth tungsten for aluminum (its the one with a grey band) set your AC freq to a higher setting around 80% and your balance down low (around 20%) adjust your base current to max and when using the pedal (yes, you almost have to use the pedal) peg it wide open to get the puddle started until the puddle forms, then back off the pedal accordingly.... aluminum tig is NOT something that you can learn in a few tries..... if you melted your tuingsten, either, your torch is hooked to the wrong polarity or your balance is too high or youa re using too small a tungsten... if you are tryign to tig anything 1/4 inch and thicker with that machine, best of luck, it does NOT have enough power to do so without a stable pre-heat and really knowing how to read an aluminum puddle... now to find the links

---------- Post added at 01:49 AM ---------- Previous post was at 01:42 AM ----------

Welding Aluminum...How to with pics inside!!! <------ post number 36 in this thread

[Wecf]

Thanks for the response!
I do have some 3/32 2% Ceriated (grey) tungsten I'll give it try. I had my AC freq. maxed out so I'll back it down. Also I had the balance at around 80% so back that down also. I always use the pedal (figured out real quick that it is the way to go with steel) so no problem there. I have my torch hooked up to - polarity, that is correct right? The ALU is 1/4 inch though. Do I need to source some thinner scrap? I do have an oxi/acet. set up can I use it to pre-heat the metal? Thanks again for your help! Now I have some reading to do....

[Gadget]

Torch is correct. It should be on the negative terminal.

[SAS Company]

Straight Argon gas is all I have ever used on aluminum. You might want to run your flow up to 20-25cfh. The end of your tungsten should get a ball or non pointed shape. Make sure the aluminum is clean too. A stainless brush that has never been used is great for that.
The "wet" area of the puddle is more subtle on aluminum than steel, right up until the whole area turns liquid and falls out! It's almost a dark art. Trial and error is the way to teach your eye what looks right and what does not.

[SICFabrications]

wecf, the flow rate given earlier is correct, however, the flowmeter provided with the longevity machines are metric.... 20 lpm is ALOT more than cfh.... pay attention.... the reason why you melted your tungsten is because your balance was too high... you will gain confidence with steel and stop using the pedal on steel.... you wont ever get away from a pedal or slider on aluminum.... you can use the oxy-acet torch to preheat the metal, just dont get it too hot.... around 200 degrees is desired for preheat..... you CANNOT use mapp, propane, propylene or other LP fuel to preheat aluminum.... it puts too much moisture on the base metal....

[tigqk]

wecf, I have put this book online on this forum to help out new users;"Mathers - Welding of Aluminum and its Alloys", but could not find it so repost it.
It is pretty iffy whether you can get a puddle going on 1/4 inch aluminum with the 256pi, so start on thinner chits of 4043.
The 256Pi is a fine machine, I have a 200PI and use it pretty much daily.Anyhow it has been a long day already.
Good Luck

[SAS Company]

borderline hijack here, Stan when would one use 250 hz frequency tig welding? I have only ever used fixed frequency machines.

[LONGEVITY-Support]

Hello wecf,

If you need help setting up your unit please call so that we can walk you through the settings for aluminum and any other questions you may have about the unit, toll free number (877)566-4462 ext.204, sorry for the delay in the response as we were on vacation for Labor Day, thank you for your time and have a wonderful day.

Best,

DP

[SICFabrications]

wec, i might get in trouble for stating this, but i will do it anyway... here's the real deal... the longevity machine boasts 250 hertz frequency instead of the 60 hertz that is standard electric in the u.s. however, the frequency is actually based off the pulser and is not correct. you should not use pulse while welding aluminum cause youre using the pedal.... now, in the correct procedure, when the frequency actually changes the sine and cosine waves of AC electricity from 60 hertz to whatever, this is what happens to the arc.... the lower freq's will widen and flatten out the puddle, making the puddle alot more fluid, its drawback will be a larger HAZ (heat affected zone) when you change the freq into the higher ranges it actually "focuses" the arc, giving you close to the same "pinpoint" arc that is found while welding steels with a sharpened tungsten... high freq adjustments will give you a very precise small and ridged puddle.... its drawbacks are this, it is wicked hard to push the puddle... you'll spend alot of time trying to chase the puddle, but you can weld thinner metal with a smaller HAZ...

this is why you must sharpen your tungsten on inverter based tig machines... the old transformer based machines are stuck at 60 hertz and will perform best with a balled end and a pure tungsten (green band) a green band tungsten is NOT for use in an inverter absed machine


if my spelling is goofed or my grammer is fudged, its alright, i've got us working 12 to 16 hours a day lately and i am tired =))

wec, hope ive helped....

this will be my LAST tech help on this forum