TIG Anguish :( Can't Fillet or Lap weld Aluminium

If I had the machine I would certainly sort out Al TIG... as you say once dialled in you will have much better control. MIGing 3mm you gotta be quick on the gun, hot ally flows quicker than water!

Have you played around on <weldingweb.com> maybe do a search before getting flamed but plenty of pro welders on that board. They seem a little anti MIG for Al and are always recommending spool guns and what not (bad for me!) but in regards to TIG Im sure they will give you some leads on your dramas.

Steve

That's a good welding website - just spent an hour reading articles on TIG, so thanks for that link.

I started to do Aluminium TIG welding at TAFE [Techbnical College] on a Kempi welder. My son is an aprentice welder and learned TIG at TAFE on a Kempi.

Aluminium oxidises on the surface and that has a higher melting point that the aluminium just under the surface.

Perhaps their is a local TAFE where you can learn to TIG weld aluminium. It is worth while Ib believe, and the best way to go with aluminium.

Spudboy, my dad grew up in the Adlaide Hills [Mount Barker], and I lived there for a a couple of years fifty years ago.

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Originally Posted by spudboy

I have gone through a whole bottle of Argon practicing :eek: Wonder how much that will be to refill....

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That's about what I used to get my eye in. It takes hours of practice and lots of scrap.

I found that while I fiddled with the machine, I wasn't improving. I set everything to where I thought it was pretty right and then concentrated on my technique - that's when I began having success.

I also use 2.4mm Zirconiated tungstens for 3mm aluminium with 2.4mm filler wire. You can get away with a 1.6mm tungsten if your machine allows you to set the AC phase balance. If you set it to more penetration (more electrode negative time) the smaller electrode won't over heat and ball up too much.
I found I had better success with a bigger shroud (#6 or 7 I think - will check tomorrow). I can't remember the gas flow rate (because I don't touch it anymore) but I think it is set to 9L/min.

I also found this a very good resource for understanding the technical side of the TIG process.
Miller - Resources - TIG Handbook

And this video was good to illustrate the correct technique.
[nomedia="http://www.youtube.com/watch?v=rR8Rlpf0ELQ"]YouTube - Tig Welding Aluminum - How to Tig Weld Aluminum - Aluminum Tig Welding Beads[/nomedia]


and practice, practice, practice ....

Just a quick follow up to this.

I got a new bottle of Argon, and hey presto - altogether different welding. I can now do nice shiny 'proper' welds that don't spit and erode half my sheets.

BOC (where I bought the Kemppi welder from) have been beyond brilliant. The regional sales rep visited my farm and took a look at the welder in situ to see if they could see what the issue was. Soon as we put on the new bottle of gas it was like a different machine. They are going to credit me for the dud bottle, which is very nice of them.

The bloke was there for over an hour and explained settings etc and got me to do some welds while he watched my technique.

So - high praise for BOC and now I can get started on my project :D

That's awesome news Spud , great to hear and as i'm sure you have already found out, a good ally weld looks as sexy as hell by comparison to a ally mig weld. Good luck with your project. Sadly i have had to delay mine til for a few months however it to is a ally project so keep us updated and we can compare notes.
Bad gas was something that i would never have considered either in fact as far as argon goes it's the only time i have ever heard of it!!!!
Happy welding mate