250DX AC Aluminum Weld Issue

[dmost]

This is what I'm getting on 1/8" 6061 aluminum with 4043 filler. Looks awful and I have no idea why. It has a lot of impurities and the weld is very undefined. I have my argon around 15. My settings I'm roughly on are: 125amps, Preflow-3s, Postflow-10s, Freq-150, Balance 90, HF start, No pulse.

I'd love help on this because I bought this machine to mainly weld aluminum and so far I'm screwed. I've been welding 304 Stainless with it for the last 3 weeks and it's been awesome. Just wish aluminum was the same.

[performance]

Well,
For starters, I can tell you haven't read the manual by the settings you posted.
In fact we have plenty of information on this site about the settings, and there are videos online that discuss them as well.
You have your balance so far off, that it's near impossible to get a good weld.
Please read the manual, and if you don't have it, download it from our website.

Set your balance to 30% and it's weld fine.

[zoama]

Do you have a 200DX or a 250EX ?... there is no "250DX" per your title.
A picture of the entire front of your machine to show settings and setup helps to solve problems.

[joshuab]

You have your argon on 15. Is that 15 lpm (the default unit for the flow-meter Everlast ships out with their units) or 15 cfh (the standard unit used in the U.S.)? A good starting point for argon flow for TIG is about 7 lpm, which equates to about 15 cfh. The best-case scenario if your flow rate is too high is you are wasting gas, but it can also compromise your gas flow, counter-intuitively. (More gas = less coverage? Possibly.)

[performance]

New regulators are in cfm and lpm (most of them anyway).

[joshuab]

New regulators are in cfm and lpm (most of them anyway).

Pardon--did not know. That's pretty cool, though. That has been one niggling complaint of the US-ians who buy Everlast.

[dmost]

You have your argon on 15. Is that 15 lpm (the default unit for the flow-meter Everlast ships out with their units) or 15 cfh (the standard unit used in the U.S.)? A good starting point for argon flow for TIG is about 7 lpm, which equates to about 15 cfh. The best-case scenario if your flow rate is too high is you are wasting gas, but it can also compromise your gas flow, counter-intuitively. (More gas = less coverage? Possibly.)

I believe it is 15lpm. I'll have to double check. The regulator has both cfh and lpm so I could be wrong.

[dmost]

Do you have a 200DX or a 250EX ?... there is no "250DX" per your title.
A picture of the entire front of your machine to show settings and setup helps to solve problems.

My apologies I have the 250EX. I've listed all the appropriate information that would be shown in a picture. If there is some setting I missed you could easily ask.

[zoama]

My apologies I have the 250EX. I've listed all the appropriate information that would be shown in a picture. If there is some setting I missed you could easily ask.

Do you hear a difference between AC and DC arc when switched ? The DC arc is a quiet hum while the AC arc will sound more harsh.
A picture is still better than playing 20 questions. None of us are perfect, sometimes we miss things.

[performance]

Guys, The balance was set at 90.
Welding TIPs and Tricks DID NOT say to weld at 65%. Please, go back and watch it carefully again...He said that on some brands of units the setting was 65% of EN. But he also acknowledged that the setting used on the Everlast unit was 35%. This is a percent of electrode positive. The MANUAL is very clear about this, and even gives suggested settings. The problem was definitely the cleaning at least at the root of it. Too much gas flow may be an issue too. If it's LPM, you don't need but 7 or so. But that is going to depend upon cup size. I'd start with a 5 or 6 and start with 5 lpm for the 5, 6 lpm for the 6 etc.

[dmost]

Well,
For starters, I can tell you haven't read the manual by the settings you posted.
In fact we have plenty of information on this site about the settings, and there are videos online that discuss them as well.
You have your balance so far off, that it's near impossible to get a good weld.
Please read the manual, and if you don't have it, download it from our website.
Set your balance to 30% and it's weld fine.

I'm going off of what I've watched on Welding tips and tricks with this exact welder. I started at 65-70 balance and it wasn't any better. I also went much lower in the 20's and 30's and was still getting the same problems.

[nils]

I have not read all the replies, so if this has been mentioned already, sorry. It looks like in the picture you posted of your machine, that your torch is plugged into the positive terminal. I think I see the gas hose jetting out from the left side of the connector. This is incorrect. Your torch for TIG should be in the negative port and the work clamp in the positive. Switch these accordingly and things should improve. Remember, to set the balance back to appx 30%. Also, be careful where your machine is in proximity to your work. The cooling fan blows out the front and sides on my 250 and it will wisp the argon right off the job.