Just finished hooking up the 250EX today

[FordSloman]

After months of working with Aluminum only, I found it difficult to Tig mild Steel at first.

I would say, the mild steel is more flexible for TIG welding. Aluminium cannot be welded without a filler rod (I cannot do that for sure), and one is very sensible for temperature, so you have to preheat the parts or you should use a pedal to control current. On other hand, I use to weld some tools made of mild steel without a filler rod using 2T mode and it really works.

[CGCINC]

Aluminium cannot be welded without a filler rod

I Tig welded this Aluminum box in welding class without filler rod. It was 1/8" material with an overlapping corner joint and I just pulse welded it using the extra material overlapping for filler

[FordSloman]

I Tig welded this Aluminum box in welding class without filler rod.

It's a nice box! I will try to weld aluminium corner w/o a filler rod someday. Did you try to weld such seams w/o pulse or this is the only way to make the magic? Btw, which pulse mode did you use? I believe it was HI pulse >100Hz?
The only joint I could weld w/o a filler rod is an edge joint, and a butt joint cracked right after I finished to weld. So, I suppose it could be done technically, but it might be not reliable.

[Rodsmachineshop]

that looks awesome really nice welds. the pulse is really nice i sure like it on my 250ex

[Rodsmachineshop]

lol i have not even welded steel with my 250ex and have had it for over 2 years now

[CGCINC]

lol i have not even welded steel with my 250ex and have had it for over 2 years now

What do you weld with it? Just Aluminum

[Rodsmachineshop]

yes mostly cylinder heads that are cracked . lots of boat and jet ski exhaust and thick aluminum , most steel i stick or mig lots of cast iron also with stick . if i had the bucks would like a spray welder to do cast iron spray weld like about 20 thousand dollars