Welding Aluminum...How to with pics inside!!!

[huck_this]

First and foremost, you have to remove the oxidation from the surface. Bring the aluminum to bare condition.
If not you will get contamination and it will be hard to start.

Here are the machine settings. You might have to play around a bit, but here is a start. Remember,
aluminum is very inductive, so heat really transmits well throughout the part than say steel. In steel,
the heat stays locally around the welding area.

So when you get near the end of your part, reduce the current by lifting off the pedal.
The reason is your parts will just blow through (melt away)


















Make sure you use a new Tungsten tip and keep it for Aluminum as well. I use the 1.5% Lanthanated type. They work just as fine.










I got good penetration here




Balling on end of tip.

[HerbD]

huck_this,

Great shots

Thanks for the info and pics. Really helps.

HerbD

[KHK]

Great picks!! thanks for sharing.

keith

[LONGEVITY]

Very nice and informative thread. Thank you for sharing.

[arandall]

Wow!! Nice weld

Art R.

[henrym]

good pictures!

now can you show us how to do it DCEN? I hear it's feasible, but awkward...

[arandall]

Huck-this:
What size electrode did you use? And how did you get the tip ground so nicely? - And bye the way, the close ups are really good. You must know your way around a camera as well.

Cheers,
Art R.

[huck_this]

Huck-this:
What size electrode did you use? And how did you get the tip ground so nicely? - And bye the way, the close ups are really good. You must know your way around a camera as well.

Cheers,
Art R.

3/32" dia. The balling occurs due to the AC. I have a medium grit and fine grit grinding wheel on my bench grinder just for my tungsten. Never use anything else on the wheel as to not contaminate your tungsten.

[Gadget]

I found my belt sander does a fine job of pointing my electrodes. I chuck the electrode in my electric drill to rotate it as the belt passes under it. Nice straight grind and the grind marks run along the length of the tip.

[huck_this]

.... I chuck the electrode in my electric drill to rotate it as the belt passes under it. Nice straight grind and the grind marks run along the length of the tip.

Cheater!!!!! I turn mine on the wheel with my welding gloves on!!!!