Aluminum paramater settings

[cdale2002]

Here is a basic starting point that you can try for 1/8 to 1/8 fillet weld using pulse which I used to welded in the pic below as labeled. I also included a sketch of a good type of point to sharpen your tungsten to (I'd recommend using either 1.5% lanthanated or 2% ceriated). What happens is the small plateu will round over, but will give a good amount of arc starting and allows you to more precisely pin point the arc (I tried the same setup we use on the millers at our shop using 1/8 Zirconium with a completely round tip and the PM256 didn't really like starting the arc along with limited control of the arc). I also used a #7 cup with a 3/32 ceriated tungsten and about 180 amps. Hope this helps.

[performance]

The manual shows the same type sharpening structure, but actually, it should be about 2.5 times the width of the electrode. A very slight truncation is all that is needed, and the units should start fine.

A needle point is fine as well, particularly on fine seams and small electrodes. It'll eventually form a dome and that is perfect. I have also used Thoriated with exceptional results on Aluminum, with the Everlast product. You can get exotic with the electrode selection, but it is not necessary to get a great looking weld or easy start.

Which Millers are you using at work? Dynasty or Synchros? Synchros are transformer based and are not similar at all in their electrode requirements. Now, a Dynasty, is another story. But even so, different brands do have their favorites. Have you tried plain 2 percent thoriated?

[cdale2002]

We have only syncrowaves, but have tried to get them to try the newer dynasty 350 seeing that they will only buy miller machines. The inverter machine deffinatly is a learning curve because almost noting that works on the transformers can be tranfered to the inverters, sort of like learning to weld again. The local weld store was telling me that the even the new transformer machince, people are using the more exotic tungsten more and more now. It's been a while since I've used thoriated mainly because at work 95% of the stuff we do is aluminum but will have to try it again. I like to experiment with different things to see what works better, you never now unless you try it if you know what I mean

[dwdw]

That Is GREAT information and for someone that doesn't do much aluminum welding with TIG its a God sent!!
I'll bet you will be appreciated by everyone that is starting out with the PM-256 or ant other TIG inverters.
Guess tomorrow I'll be trying the settings!!
Mike or Mark maybe this would be a STICKY!!
Thank You
dwdw

[performance]

Looking at your basic setting, you have too much cleaning for the average weld. You may experience some loss of arc stability and DEFINITELY have an issue with the tungsten getting too hot at about 70% DCEP. I'd recommend turning it down to about 30%-35% to start. That gives much better penetration and is sufficient for arc stability. If you are using it at 70% and find it is necessary to get good welds, make sure you have the torch hooked up to the negative terminal. This will cause the setting to be reversed, and cause all kinds of frustrations.

[cdale2002]

Looking at your basic setting, you have too much cleaning for the average weld. You may experience some loss of arc stability and DEFINITELY have an issue with the tungsten getting too hot at about 70% DCEP. I'd recommend turning it down to about 30%-35% to start. That gives much better penetration and is sufficient for arc stability. If you are using it at 70% and find it is necessary to get good welds, make sure you have the torch hooked up to the negative terminal. This will cause the setting to be reversed, and cause all kinds of frustrations.

correct me if i'm wrong, but isn't the AC balance the control over say 10% is maximum cleaning and 90% is maximium penentration. So your saying that 70% is way to much, but every welder I have tried and used liked it anywhere from 60-80% (On the syncros I like using 70-80%). But I'll try turning it down to what you said on the next part. Don't take it as if I'm questioning your knowledge because this machine has been a little bit of a learning curve for me compared to the the transformer machines I'm used to.

[performance]

Miller apparently does things backwards from the other guys in the industry.
The balance control is % DCEP not DCEN on our welders, and most others that I have seen. I was thinking this was most of Millers way of doing it as well. I guess they must have changed at some time.

Positive electrode concentrates the heat on the electrode and takes it away from the material. A higher positive concentration not only increases the size of tungsten needed for the job, but it also requires more amperage input to do the same work.

[cdale2002]

had to look for myself, it appers that miller does use dcen so that would put me at 75% dcen on a miller (just about what I use at work) which is the same as the recomended number of 35% you gave me. Didn't know they were dcep, learn something new everyday. Thanks for the advice.

[dwdw]

Good news the settings were a good start! Mark your correction did make it easier to concentrate on the clean area. I can't wait till it warms-up its just to cold in the out-building. The cables are so stiff that you can't move the Tig torch smoothly! Like welding with an old Chevy coil spring 15' long!
Thank You
dwdw

[performance]

If ya'll will notice, under the AC balance control, there is a - and + sign. We added this to give you a clue which direction you were heading when you were adjusting it. I guess it wasn't a strong enough hint.:wink: