Help noob with aluminum

[MrMega]

I recently purchased a power tig 200dx. I've managed to get the hang of welding steel and even welded some copper, but I am having a terrible time with aluminum. I am just trying to put some beads on some 1/8" flat bar but it just isn't working. As soon as I get it hot enough to get a puddle or melt the filler rod it simply melts a hole through the material. I've tried different settings with the frequency and AC balance but it is always the same result. I have adjusted the gas flow and cleaned and re-cleaned the material with no success. I have attached photos of the top and bottom of the bar. The bubbled side is the bottom. Please help if possible.

Thanks,

Forrest

[zoama]

You need to practice on a larger piece that won't be so heat sensitive, like 6"x6"x1/8". It helps to know the alloy since some aluminum alloys aren't weldable. You need to have the AC balance just high enough to breakup the oxide layer and get a shinny puddle. Keep your filler inside the shielded area around the arc and remember that the puddle melts the filler, not the arc. Dipping the filler cools the puddle so you can use that to control heat also.

[performance]

As with any of these threads, there's not much we can help you with unless you give us your settings. Anything else is stabbing in the dark on things. I see a little contamination which could be a sign of contaminated gas or too much torch angle or a leak.

But without knowing your settings for gas flow, torch polarity, AC balance, AC frequency, amps etc. it really is hard to help more than a few generic suggestions.

From what I see too it possibly could be you are holding your torch way too high off the metal due to the width of the bead. Pull it down to a height no more than a penny or quarter's thickness off the metal.

Puddle recognition in Aluminum is somewhat different. The metal doesn't change color. It gets a little slick sweaty, greasy silver looking and then it's time to add by the time you see that. It's a thin line between full blown puddle and falling through.

[MrMega]

Thanks for the advice. I practiced with some thicker material and used a larger gas nozzle. I got it down pretty good after a few hours and made some great looking welds on the 1/8" material as well. It was fairly simple once I learned to recognize the fine details. I was also surprised that welding with unclean material and tungsten wasn't really that difficult.