Having a difficult time with Pulse-GMAW of Ali in greater thicknesses.
Compared to previous happy times where after a very few days I'm considered the master of the job.
Do not have yet a "model" or "multi-dimensional map" giving a rationale of where to find the best conditions for new situations with Pulse.
Previously I've used
- spray transfer for anything >=10m/min wire-feed-speed
- pulse only for thinner low heat demand things like outside-corner welds sealing end-cap plates onto Al-Si-Mg 6082 extruded Rectangular Hollow Sections
So I'm trying to Pulse where previously I've used spray.
Thicknesses... Mostly 5mm (in 5083 (marine Al-Mg) plate) (* (/ 5 25.4) 16) 3.1496062992125986 which is just under 3/16" plate thickness. So not great thicknesses (done 1/4" sections to 3/4" plate Ali before)
The machine has two knobs at the wire-feeder. One increases the thickness it is supposed to be welding on - and it reports the Amps go up seemingly in proportion. The other is a "trim" which might be related to Voltage?
I only have a list of welding conditions which worked in specific cases. I wish that like eg. doing any spray-transfer I have a "map" of the "contours" of good conditions and can see from a small test weld where I am in the "map" and have a very accurate guess of where I need to be to land on good conditions for a new previously unfamiliar job.
I have seen very good welds where I would be using Pulse anyway, so don't doubt the machine (well, I've seen others sink into "anglo-saxon" borrowing it and finding glitches, but anyway...)
I sometimes end up with good welds but fillet sizes bigger than called for because there simply does not seem to be the fluidity to run beads at the minimum size.
So - Pulse GMAW Ali (aluminium, aluminum) - anyone point me to a way of seeing an overarching sense for it? Build that "multi-dimansional contour map" to know where to look for the good conditions in any new circumstance?
Thanks in advance