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).

[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.

[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.

[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.

[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.

[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.

[everlastsupport]

You want to set up about 30% on balance and 120 or so on frequency. If you watched Jody's videos with the 250EX you can see the knobs are about 2 o'clock and 10 o'clock left to right. Also, if you run 7 LPM you should be just fine.

The information has been covered many times here on the forum and like Mark said it's covered in the manual. But that should get you straight. Post up some new shots so we can see.

[dmost]

You want to set up about 30% on balance and 120 or so on frequency. If you watched Jody's videos with the 250EX you can see the knobs are about 2 o'clock and 10 o'clock left to right. Also, if you run 7 LPM you should be just fine.

The information has been covered many times here on the forum and like Mark said it's covered in the manual. But that should get you straight. Post up some new shots so we can see.

Well as Mark said I read the MANUAL and set the balance to 30%. No real big change in the weld. Still getting a lot of impurities and almost like a black foam covering while I'm trying to weld. I also tried it from 0-40% after the initial 30% didn't do much. I will include images below. Also my torch decided it didn't want to flew anymore and split at the neck. I have only had this thing for a few months. See the images below for settings and torch pic.

[zoama]

The welds look like the result of poor gas coverage or air mixing with the shielding gas. Upgrade to a CK torch with a superflex lead and you'll be much happier. Everlast sells CK, plug and play for their machines.

[Rambozo]

Those welds have air contamination. You have a shielding gas problem. Probably the torch was leaking even before the split was visible. What size cup are you using? It looks on the small side for the width of the beads you are trying to run. What flow rate were you using and did you check everything for leaks? Even a tiny leak at the torch will suck in air and ruin your welds.

[dmost]

Those welds have air contamination. You have a shielding gas problem. Probably the torch was leaking even before the split was visible. What size cup are you using? It looks on the small side for the width of the beads you are trying to run. What flow rate were you using and did you check everything for leaks? Even a tiny leak at the torch will suck in air and ruin your welds.

I was running at 15cfm and as far as I know it wasn't leaking. Only gas flow I've ever heard was threw the cup. I was using a 6.

[dmost]

The welds look like the result of poor gas coverage or air mixing with the shielding gas. The warranty on accessories is 90 days. Upgrade to a CK torch with a superflex lead and you'll be much happier. Everlast sells CK, plug and play for their machines.

Well I'm definitely in that 90 day window. Since when do they sell CK? They don't have any on their site under tig torches.

[zoama]

Well I'm definitely in that 90 day window. Since when do they sell CK? They don't have any on their site under tig torches.

They just started a while back. They have a new website in the works but until that's up, just call sales. CK torches are rated at 100% duty cycle in both AC and DC.

[performance]

We've sold CK about a year now. You call in to order and its by word of mouth mostly. We are adding them to the new website.
The torch is warrantied for 6 months. We can ship you a new one. The torch will split usually from over heating, but that can happen in several ways, not just amps. Running too high of cleaning really heats up the torch and reduces the duty cycle of the torch. But as I said, it is under warranty if it's under 6 months.

What tungsten are you using? Running a point or ball?

It can also be a case of contaminated gas...which is not all that uncommon these days.

[dmost]

We've sold CK about a year now. You call in to order and its by word of mouth mostly. We are adding them to the new website.
The torch is warrantied for 6 months. We can ship you a new one. The torch will split usually from over heating, but that can happen in several ways, not just amps. Running too high of cleaning really heats up the torch and reduces the duty cycle of the torch. But as I said, it is under warranty if it's under 6 months.

What tungsten are you using? Running a point or ball?

It can also be a case of contaminated gas...which is not all that uncommon these days.

2% lanth. For aluminum balled, pointed for steel. Nice to know the torches are 6 months warranty. What do I do to swap out the torch? Or swap it out for a CK torch? Does a CK use the same internal hardware?

Surprised to hear contaminated gas is not uncommon, that's the last thing I'd assume. Pretty sh**ty that's another variable I need to take into consideration now.