I've rally been asking the aluminum welding questions for my son.
He's the better welder in the family and I have him working on my
project. (See:http://unreasonablerocket.blogspot.com/)


Tonight my son spent some time with a local gentelman (Bob) that does
aluminum welding. And he/we learned some things:

1)He was having no luck whatsoever welding aluminum here using our
Thermal Arc
http://www.thermadyne.com/evolution/brandProductSpecific.asp?mernbr=1&div=tai&catnbr=99&pdtnbr=567

2)He was quite successful welding things using Bobs miller welder.


The difference between samples on the same peice of aluminum from
heree to there was stunning, one was really really bad the other
looked like a good weld.

Its real clear that our aluminum welding problem is some very
fundamental bad setup with the equipment.

I've rally been asking the aluminum welding questions for my son.
He's the better welder in the family and I have him working on my
project. (See:http://unreasonablerocket.blogspot.com/)


Tonight my son spent some time with a local gentelman (Bob) that does
aluminum welding. And he/we learned some things:

1)He was having no luck whatsoever welding aluminum here using our
Thermal Arc
http://www.thermadyne.com/evolution/brandProductSpecific.asp?mernbr=1&div=tai&
catnbr=99&pdtnbr=567

2)He was quite successful welding things using Bobs miller welder.


The difference between samples on the same peice of aluminum from
heree to there was stunning, one was really really bad the other
looked like a good weld.

Its real clear that our aluminum welding problem is some very
fundamental bad setup with the equipment.

So is there anyone on the group that uses this welder that can give me
the step by step exact settings they are using for aluminum?

When doing TIG on aluminum how do you start?
Lift, scratch, HF other????

I always thought that lift start was best, bbut tonight was told
different. How do you start the arc with aluminum?


Paul

I've rally been asking the aluminum welding questions for my son.
He's the better welder in the family and I have him working on my
project. (See:http://unreasonablerocket.blogspot.com/)


Tonight my son spent some time with a local gentelman (Bob) that does
aluminum welding. And he/we learned some things:

1)He was having no luck whatsoever welding aluminum here using our
Thermal Arc
http://www.thermadyne.com/evolution/brandProductSpecific.asp?mernbr=1&div=tai&catnbr=99&pdtnbr=567

2)He was quite successful welding things using Bobs miller welder.


The difference between samples on the same peice of aluminum from
heree to there was stunning, one was really really bad the other
looked like a good weld.

Its real clear that our aluminum welding problem is some very
fundamental bad setup with the equipment.

So is there anyone on the group that uses this welder that can give me
the step by step exact settings they are using for aluminum?

When doing TIG on aluminum how do you start?
Lift, scratch, HF other????

I always thought that lift start was best, bbut tonight was told
different. How do you start the arc with aluminum?


Paul

HF is easiest to start and doesn't contaminate the weld.
Was using Lift start now using HF.

What Tungsten are you using? (Size, type)
1/16 Pure tungston.

Did you clean the aluminum to be welded with SS brush?
Yes

Did you use A/C setting on the TIG box?
Yes

What gas are you using? (Make SURE it's Argon.)
Argon

What rod are you using. (Don't use steel rod to weld aluminum, don't ask
Aluminum 1/8" Rod from the welding store where the compatibility charts lists it as reccomended for 6061.

Welding outside or inside. (Wind or drafts blow shielding gas away.)
Inside.

If your welding ok with one machine but not another. Jot down the list
above and note any other settings that are working well on the machine
that welds OK.

HF is easiest to start and doesn't contaminate the weld.
Was using Lift start now using HF.

What Tungsten are you using? (Size, type)
1/16 Pure tungston.

Did you clean the aluminum to be welded with SS brush?
Yes

Did you use A/C setting on the TIG box?
Yes

What gas are you using? (Make SURE it's Argon.)
Argon

What rod are you using. (Don't use steel rod to weld aluminum, don't ask
Aluminum 1/8" Rod from the welding store where the compatibility charts lists it as reccomended for 6061.
(I'm not at home so I cant look at the package)

Welding outside or inside. (Wind or drafts blow shielding gas away.)
Inside.

If your welding ok with one machine but not another. Jot down the list
above and note any other settings that are working well on the machine
that welds OK.

The welding is going much better, but the start up still seems to make a big black blob
more often than not, the other machine did not.

Paul

HF is easiest to start and doesn't contaminate the weld.
Was using Lift start now using HF.

What Tungsten are you using? (Size, type)
1/16 Pure tungston.

Did you clean the aluminum to be welded with SS brush?
Yes

Did you use A/C setting on the TIG box?
Yes

What gas are you using? (Make SURE it's Argon.)
Argon

What rod are you using. (Don't use steel rod to weld aluminum, don't ask
Aluminum 1/8" Rod from the welding store where the compatibility charts lists
it as reccomended for 6061.
(I'm not at home so I cant look at the package)

Welding outside or inside. (Wind or drafts blow shielding gas away.)
Inside.

If your welding ok with one machine but not another. Jot down the list
above and note any other settings that are working well on the machine
that welds OK.

The welding is going much better, but the start up still seems to make a big
black blob
more often than not, the other machine did not.

Paul