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Arc wandering on AL

In my pursuit of being able to weld aluminum I have come across something that I can't figure out how to fix.

I have a ThermalArc 185TSW, AC, HF start, 55 amps, 1/16 pure tungsten trying to weld 0.055" 3003 sheet aluminum. I clean the AL with a stainless brush, then with a paper towel with a dab of acetone for good measure. I have 1/16" 4043 filler, wiped clean with acetone.

When I strike the arc it seems to be actually jumping about 3/8" from where it should be. I am expecting, and have seen the puddle start to form directly under the tungsten, on other times.

I have expiremented with larger gaps and holding the torch at different angles. I think I have seen this with both a brand new blunt tungsten and one of my used tungstens, that may have been contaminated with a little AL.

I have been able to lay a reasonable bead on a flat plate, but have not sucessfully been able to get a butt joint welded together. I wish someone had a movie online so I could see what I'm not getting...

Rod

Reply to
Rod Richeson
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I just got a new ThermalArc 185 this week, and haven't tried Al yet, but just curious how you are grinding your tungsten ? What I do (and brand new to this), is chuck up the tungsten in a cordless drill, and stick it down into that small Delta 30" (1-inch wide) belt sander. To get the right angle with a full length electrode, you gotta stick it down in below the little table to where the chuck of the drill is hitting the top of the housing, and press it against the belt with moderate pressure while spinning the drill very slowly. Also check inside the pink cup for debris.

But being brand new to TIG, and the ThermalArc 185, I'll be walking in your footsteps. PS, have you tried to stick weld with it, and are you able to strike an arc Ok ?

Reply to
Mr Wizzard

Sounds like Arc Blow. Usually caused by a magnetic field. Try moving your ground clamp, and make sure you don't have any big magnets nearby.

The Thermal Arc 185TSW has variable AC wave frequency. If you increase the frequency it should narrow the arc down to a smaller cone, much like DC TIG.

Another tip. Try bringing up the heat very slowly on the end of the filler rod, as it sits in the joint. Melt a small ball off the end of the filler so it is sitting in the joint. Now directly heat the ball until it wets out to both pieces. This will start your fillet weld.

Your amps are a bit low.

0.055" aluminum = 55 amps for a flat butt weld, single pass full penetration.

A fillet weld is + 33% so that would be 55 + 18 = 73 amps.

So set your machine to 75 amps , and it should work better.

Also your rod is a bit large. Try not to use a filler that is thicker than your base metal.

0.045" rod is better choice.
Reply to
Ernie Leimkuhler

I'll second what Ernie said. I used some magnets to secure thin aluminum for practice welds. Arc was ALL over the place. (That and the A/C that was blowing in my garage.)

Lost the magnets and all is fine. I imagine that this would be applicable to steel as well. (Like for the magnetic ground posts you see in Harbor Freight.)

Bart

Reply to
Bart D. Hull

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