Welcome to the North American Subaru Impreza Owners Club Friday March 29, 2024
Home Forums Images WikiNASIOC Products Store Modifications Upgrade Garage
NASIOC
Go Back   NASIOC > NASIOC Technical > Custom Fabrication, Welding & Tools

Welcome to NASIOC - The world's largest online community for Subaru enthusiasts!
Welcome to the NASIOC.com Subaru forum.

You are currently viewing our forum as a guest, which gives you limited access to view most discussions and access our other features. By joining our community, free of charge, you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is free, fast and simple, so please join our community today!

If you have any problems with the registration process or your account login, please contact us.







* As an Amazon Associate I earn from qualifying purchases. 
* Registered users of the site do not see these ads. 
Reply
 
Thread Tools Display Modes
Old 02-04-2017, 05:17 PM   #1
Bad Noodle
Scooby Specialist
 
Member#: 174442
Join Date: Mar 2008
Chapter/Region: Tri-State
Location: NNJ
Vehicle:
2007 SuperWagon
I don't spell well

Default 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!
* Registered users of the site do not see these ads.
Bad Noodle is offline   Reply With Quote
Sponsored Links
* Registered users of the site do not see these ads.
Old 02-04-2017, 05:37 PM   #2
Dr.Subie
Scooby Newbie
 
Member#: 461990
Join Date: Jan 2017
Chapter/Region: MWSOC
Location: Brainerd, MN
Vehicle:
2002 Legacy Wagon

Default

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!!!
Dr.Subie is offline   Reply With Quote
Old 02-04-2017, 06:38 PM   #3
Bad Noodle
Scooby Specialist
 
Member#: 174442
Join Date: Mar 2008
Chapter/Region: Tri-State
Location: NNJ
Vehicle:
2007 SuperWagon
I don't spell well

Default

^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 ...
Bad Noodle is offline   Reply With Quote
Old 02-04-2017, 06:58 PM   #4
Dr.Subie
Scooby Newbie
 
Member#: 461990
Join Date: Jan 2017
Chapter/Region: MWSOC
Location: Brainerd, MN
Vehicle:
2002 Legacy Wagon

Default

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.
Dr.Subie is offline   Reply With Quote
Old 02-04-2017, 07:41 PM   #5
Bad Noodle
Scooby Specialist
 
Member#: 174442
Join Date: Mar 2008
Chapter/Region: Tri-State
Location: NNJ
Vehicle:
2007 SuperWagon
I don't spell well

Default

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?
Bad Noodle is offline   Reply With Quote
Old 02-04-2017, 08:07 PM   #6
424wrx
Scooby Guru
 
Member#: 171948
Join Date: Feb 2008
Chapter/Region: Tri-State
Location: new york
Vehicle:
19 Sti
Crystal white

Default

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.
424wrx is offline   Reply With Quote
Old 02-04-2017, 08:27 PM   #7
Bad Noodle
Scooby Specialist
 
Member#: 174442
Join Date: Mar 2008
Chapter/Region: Tri-State
Location: NNJ
Vehicle:
2007 SuperWagon
I don't spell well

Default

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
Bad Noodle is offline   Reply With Quote
Old 02-04-2017, 08:39 PM   #8
Bad Noodle
Scooby Specialist
 
Member#: 174442
Join Date: Mar 2008
Chapter/Region: Tri-State
Location: NNJ
Vehicle:
2007 SuperWagon
I don't spell well

Default

Finally success:



It just took 110 amps :/
Bad Noodle is offline   Reply With Quote
Old 02-04-2017, 08:59 PM   #9
Dr.Subie
Scooby Newbie
 
Member#: 461990
Join Date: Jan 2017
Chapter/Region: MWSOC
Location: Brainerd, MN
Vehicle:
2002 Legacy Wagon

Default

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!
Dr.Subie is offline   Reply With Quote
Old 02-05-2017, 05:54 AM   #10
Bad Noodle
Scooby Specialist
 
Member#: 174442
Join Date: Mar 2008
Chapter/Region: Tri-State
Location: NNJ
Vehicle:
2007 SuperWagon
I don't spell well

Default

^ 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
Bad Noodle is offline   Reply With Quote
Old 02-05-2017, 09:08 AM   #11
ALOKIN
Scooby Specialist
 
Member#: 348177
Join Date: Feb 2013
Chapter/Region: TXIC
Location: TX
Vehicle:
2002 Bugeye
Haltech GTX3584RS

Default

Chinesium arroy very tuff to weld. LOL. Looks good!
ALOKIN is offline   Reply With Quote
Old 02-05-2017, 09:23 AM   #12
jvangelder
Scooby Newbie
 
Member#: 358395
Join Date: Jun 2013
Chapter/Region: NESIC
Location: NH
Vehicle:
05 STI
White with Rubber marks

Default

Quote:
Originally Posted by ALOKIN View Post
Chinesium arroy very tuff to weld. LOL. Looks good!
Almost spit my coffee out on that one, im going to put this on some drawings and see how long it takes for someone to notice
jvangelder is offline   Reply With Quote
Old 02-06-2017, 08:04 AM   #13
baseballdbk1
Scooby Specialist
 
Member#: 242700
Join Date: Mar 2010
Chapter/Region: Tri-State
Location: Pittsburgh, Pa
Vehicle:
2015 Impreza Wrx
White

Default

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.
baseballdbk1 is offline   Reply With Quote
Old 02-06-2017, 10:06 AM   #14
Project04WRX
Scooby Newbie
 
Member#: 423623
Join Date: Jun 2015
Chapter/Region: MWSOC
Location: Cincinnati
Vehicle:
2004 WRX Wagon
Black

Default

Should look into using flux next time
Project04WRX is offline   Reply With Quote
Old 02-06-2017, 12:20 PM   #15
rtv900
Scooby Guru
 
Member#: 428511
Join Date: Aug 2015
Location: philadelphia
Vehicle:
2016 STI

Default

Nobody has yet asked why he's sharpening tungsten for aluminum?????
rtv900 is offline   Reply With Quote
Old 02-06-2017, 12:36 PM   #16
Bad Noodle
Scooby Specialist
 
Member#: 174442
Join Date: Mar 2008
Chapter/Region: Tri-State
Location: NNJ
Vehicle:
2007 SuperWagon
I don't spell well

Default

Woaaahhhh. You guys are awesome! That you for all the constructive feedback!
Bad Noodle is offline   Reply With Quote
Old 03-06-2017, 07:56 PM   #17
rick_740
Scooby Newbie
 
Member#: 464099
Join Date: Mar 2017
Default

yea, tungsten should ball up on aluminum. As for preheat, I always like some preheat to make it flow better.
rick_740 is offline   Reply With Quote
Old 03-13-2017, 08:44 PM   #18
Sedanman67
Scooby Newbie
 
Member#: 464341
Join Date: Mar 2017
Location: Beacon NY
Vehicle:
2017 Impreza Ltd 5 d
Black/black

Default

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.
Sedanman67 is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Forum Jump

All times are GMT -4. The time now is 11:58 AM.


Powered by vBulletin® Version 3.7.0
Copyright ©2000 - 2024, Jelsoft Enterprises Ltd.
Powered by Searchlight © 2024 Axivo Inc.
Copyright ©1999 - 2019, North American Subaru Impreza Owners Club, Inc.

As an Amazon Associate I earn from qualifying purchases.

When you click on links to various merchants on this site and make a purchase, this can result in this site earning a commission
Affiliate programs and affiliations include, but are not limited to, the eBay Partner Network.