I bought a 185 Micro a while back from Mark. Great guy to deal with btw. Anyways, I have not been able to get my welds on it consistent on AC when welding aluminum. It is really started to frustrate me. I've researched a ton, and still can not come up with a conclusion as to why welding AC on this machine sucks. DC was good, had no problems with it.

So here are my issues... my tungsten balls up real bad (thicker than the diameter of the tungsten) and the arc wanders everywhere. Have tried both 2% thoriated, and pure tungsten. 3/32 in size. Using a #6 cup with a regular collet body. Running 100% argon. 20cfh. I've checked for leaks, and there isn't any. I sharpen the tungsten and put a flat top on it. Tungsten sticks out about 3/8" from the cup before it balls.

Pic of the settings I'm using:



I tried welding this together till I got frustrated. Both pieces of aluminum are .090" thick. Welded on 95 amps. When I would get a puddle, the arc would make the rod real crummy, not sure how to describe it.



:sigh: .... any suggestions before I quit aluminum tig welding forever...? Not really. But I feel like that right now.