I spent a frustrating afternoon trying to weld two pieces of 3/8 aluminum 6061 plate perpendicular to each other in a "T" configuration. I have a Miller Synchrowave 250 and have done a fair amount of welding on thinner aluminum, but this was the first time I had tried anything thicker than 1/8. Machine was set for maximum amps, AC, continuous high frequency, metal was clean and gas was argon, but I just couldn't get a puddle to form that included both pieces of the aluminum. I tried using a 1/8 tungsten electrode, in case a smaller size was limiting power, but that didn't help. Just as it seemed close to forming a puddle, the metal seemed to sag a bit, the buzzing got ungodly loud, and the 50 amp breaker would trip. By then the entire weldment was very hot, but no weld. I was able to get a few short beads welding 1/8 inch-wall thickness aluminum pipe to the edge of the 3/8 plate, but it was pretty ugly. Was I simply exceeding the capacity of the machine? I had assumed that doing so would result in a lack of good penetration, but since this was just a bracket to hold a TV antenna, I was willing to live with that. Maybe, at least with Tig and aluminum, poor penetration, or insufficient amps, means no weld at all? Any ideas? Gary Hastings
- posted
20 years ago