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Problems TIG'ing thin-walled aluminum tube

Problems TIG'ing thin-walled aluminum tube

Problems TIG'ing thin-walled aluminum tube

(OP)
I'm trying to weld pieces of 6061 tube together which are .032" thick, 2.5" wide.  

I just got a Miller Dynasty 200DX and I am still learning how to use it.  I'm using a/c, 150amps, but I'm not sure of the other settings I should have setup on the machine to make a good weld.  It just wants to burn through the pipe wall no matter how delicate I am with the foot control, it goes from not melting to melting the wall and cutting back from the edge, how can I weld this joint effectively?  

If anyone knows about my welder and could help me I'd really appreciate it, I'm trying to get this project completed.

~Will

what should argon be flowing at?
what amperage should I run?
I'm using 3/32 filler wire
what about all those frequency and intial slope settings?
I'm confused!

RE: Problems TIG'ing thin-walled aluminum tube

Try these -

Welding Current 60 to 80 amp range
Travel speed - 12 ipm (5.1 mm/sec)
Wire Dia. 1/16" (1.6 mm)
Argon Flow   14.5 cfm    (7lpm)

RE: Problems TIG'ing thin-walled aluminum tube

Filler too large. Even 60 to 80 amps is too much curent.  TIG takes practice!

RE: Problems TIG'ing thin-walled aluminum tube

Manual open root, TIG welding 6061 that thin (.032")is a real art!
Recommended current: 45-55 Amps with Argon shield
Argon back purge at 8-12 CFH
0-1/32" root opening with square groove bevel
.035" ER5356 filler
Preclean (power brush)with clean stainless steel brushes  (you may wish to use a (Drimel drive system)
1/8" diameter EWP or EWZr electrode.
Travel Speed: 10"/min minumum.

And have a steady hand! Good Luck! As ornerynorsk says PRACTICE!

RE: Problems TIG'ing thin-walled aluminum tube

(OP)
I had better luck using 1/16" electrode and 60 amps, but still not great.  I will try your suggestions as far as the even lower amperage.  I do have to pick up some much thinner filler rod though, I know it's too big.  

Much appreciated!

RE: Problems TIG'ing thin-walled aluminum tube

We never have it turned up above 50 Amps.  Stick with it!  Ornerynorsk is right.

"Simplicate, and add more lightness" - Bill Stout
Steven Fahey, CET

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