- Joined
- Feb 24, 2015
- Messages
- 1,382
I got my TIG welder about a year ago. I haven't attempted to weld aluminum with it as most of the advise I saw recommended learning to weld steel first, for obvious reasons if you've ever heated any aluminum close to it's melting point.
I have a project that will require some aluminum welds so I guess it is time to practice.
My first test plate was a 3/16" aluminum plate. That's very close to what I'll be welding. I'll post plans later.
This is the set up I used. A copper base plate with the work lead clamped to my copper finger.
I had the amperage set at 120 amps, as that was the high end of recommended for 1/8" welding on my machine (Miller 210 Syncrowave). A 3/32" tungsten ground to a fairly stubby 50º point and 3/32" aluminum rod.
I chose a low amperage setting as my experience has been that aluminum melts suddenly by surprise.
The test beads shown progress from bottom to top, the bottom one being the first.
On the first bead, I made a pass without filler rod. Then I attempted to use rod on a second pass over the first.
It didn't work out very well. I allowed the plate to cool a few minutes between passes.
The second and third passes were a little better, but I was still trying to learn how far away from the arc to keep the filler rod. Too close and it balled up.
On the 4th, 5th, and 6th passes I was starting to get the hang of it. The beads were short on purpose as that is what will be required on the actual project. Still having some issues with melting the tip of the rod, but generally better. By the last couple of rows, I was learning how to dab the rod in and get it out before it melted.
I have a project that will require some aluminum welds so I guess it is time to practice.
My first test plate was a 3/16" aluminum plate. That's very close to what I'll be welding. I'll post plans later.
This is the set up I used. A copper base plate with the work lead clamped to my copper finger.
I had the amperage set at 120 amps, as that was the high end of recommended for 1/8" welding on my machine (Miller 210 Syncrowave). A 3/32" tungsten ground to a fairly stubby 50º point and 3/32" aluminum rod.
I chose a low amperage setting as my experience has been that aluminum melts suddenly by surprise.
The test beads shown progress from bottom to top, the bottom one being the first.
On the first bead, I made a pass without filler rod. Then I attempted to use rod on a second pass over the first.
It didn't work out very well. I allowed the plate to cool a few minutes between passes.
The second and third passes were a little better, but I was still trying to learn how far away from the arc to keep the filler rod. Too close and it balled up.
On the 4th, 5th, and 6th passes I was starting to get the hang of it. The beads were short on purpose as that is what will be required on the actual project. Still having some issues with melting the tip of the rod, but generally better. By the last couple of rows, I was learning how to dab the rod in and get it out before it melted.
Last edited:
. just dive in and do it. Make mistakes as you go and learn. I wish my welder did AC. Its only dc tig/stick.
