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02-04-2017, 05:17 PM | #1 |
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Can't weld bracket to AOS .... grrrrr
In short:
Can't figure out why the two won't join. Cleaned both with SS brushes many times. Then cleaned with acetone. Sharpened tungsten, checked gas, just can't figure it out. Thoughts? Help!
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02-04-2017, 05:37 PM | #2 |
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What machine are you welding with? What are your settings at? What size tungsten are you using, and what material filler rod? It looks like you may have your electrode too far from your base material, causing some premature puddling of the filler rod.
Sounds to me like you have your prep work spot on. I know how frustrating these things can be!!! |
02-04-2017, 06:38 PM | #3 |
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^thanks for the reply. Using the Eastwood tig200 set to 50 amps, er4043 3/32", and the green tungsten that came with the welder. Think it's 3/32.
I just finished welding up AN fittings onto the Crawford AOS with those settings without issue so I figured a bracket should be easy. I also welded a 1/4" block of 6061 to a 3" intake pipe without issue. Im stumped ... |
02-04-2017, 06:58 PM | #4 |
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Are you sure you haven't hooked up the torch in reverse polarity? does the tip on the tungsten ball up and try to suck up into the torch when striking an arch? If the polarity is correct, try lowering the amperage slightly and giving the gas a bump up. I assume you are using a bottle that has 100% argon and no helium mix. Also be sure you still have gas!
I know these questions sound stupid but you wouldn't believe the mistakes I have caught myself on See if you can scrounge up some scrap pieces of aluminum to clean up and give a go on first. |
02-04-2017, 07:41 PM | #5 |
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Hmm I doubled checked and still have 1/4 tank gas with 15cfm flow rate and the welder is set to AC. I'm thinking I might not be getting the can hot enough as the AOS base material is not forming a puddle. Should I heat it with a propane torch then try the weld again?
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02-04-2017, 08:07 PM | #6 |
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can you lay the can more straight up and down and concentrate the puddle into the can? ive done quite a bit of aluminum at my job but all mig.
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02-04-2017, 08:27 PM | #7 |
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I think there's something strange about the Crawford AOS material. It simply will not form a puddle. I just tried again. Here what I did:
AC selected 50 amps on the pedal 15 cfm has flow Nice sharp tungsten Preheated can to 200F Placed bracket material on can Held pedal down for a solid minute and did not get a puddle on the can Fml |
02-04-2017, 08:39 PM | #8 |
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Finally success:
It just took 110 amps :/ |
02-04-2017, 08:59 PM | #9 |
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WOW! That's way more than I would have figured, I guess if its around 2.5mm wall that would sound about right. And you may be correct about the material being a strange alloy of some sort...
I would almost bet you would have better luck with 2% lanthanated tungsten on that material. The green is 100% tungsten, which will tend to ball up and misbehave at lower amperages. Even so, good learning experience. Get yourself an array of different cups/ lenses, filler rods and electrodes and start testing them on numerous materials. A lot of machine shops will give away pieces of scrap alloy for cheap or even free, makes for great practice!! Glad you got it to stick tho! |
02-05-2017, 05:54 AM | #10 |
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^ thanks for the help. It was good to know that I'm doing the process correctly. It's my lack of experience that was messing things up
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02-05-2017, 09:08 AM | #11 |
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Chinesium arroy very tuff to weld. LOL. Looks good!
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02-05-2017, 09:23 AM | #12 |
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02-06-2017, 08:04 AM | #13 |
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I wouldn't worry about preheating unless absolutely needed...
I've had to preheat a few times on cast aluminum oil pans and valve covers but that's about it. In the future, set your amperage higher to around the 150 range for doing the type of weld you have pictured which will give you plenty of range to get the puddle started quickly and then back off slightly for the remainder of the weld. Pure tungsten aka "green" works well on aluminum with high frequency welders but I would personally recommend 2% lanthanated aka blue. Last edited by baseballdbk1; 02-06-2017 at 08:15 AM. |
02-06-2017, 10:06 AM | #14 |
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Should look into using flux next time
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02-06-2017, 12:20 PM | #15 |
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Nobody has yet asked why he's sharpening tungsten for aluminum?????
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02-06-2017, 12:36 PM | #16 |
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Woaaahhhh. You guys are awesome! That you for all the constructive feedback!
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03-06-2017, 07:56 PM | #17 |
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yea, tungsten should ball up on aluminum. As for preheat, I always like some preheat to make it flow better.
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03-13-2017, 08:44 PM | #18 |
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I use a sharp tungsten on aluminum but I also run 200hz . On a machine without adjustable ac frequency, ball the tungsten. Also try 4047 filler rod, a little more silicon makes it wet out better than 4043 but it otherwise behaves the same.
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