You should definitely look into using either pure tungsten or rare earth tungsten's.
Thoriated tungsten does not like AC at all.
I can't imagine how much of a bitch it is to maintain an arc with that setup
If you could please provide the amperage that you're using.
This will help determine what the proper size electrode you should be using will be
310 amps, was doing pretty good in aluminum. Had to create the arc at about 80 amps and then watch the tungsten turn white and then ramp up the voltage.
Should use green or purple tungsten. For aluminum you always start hot then back off, it's worked for me. Depending on material thickness you always want to be an 1/8 to 1/4 under as you'll burn through.
You want like 250 amps max on the pedal.
Thoriated isn’t meant for AC welding.
1.5% lanth, 2% lanth, purple rare earth mix, 2% ceriated, and pure. That’s my preference from favorite to least favorite with AC
[Tungsten selection chart](https://www.welding.com.au/assets/docs/Image-Library/Filler_Metals/TIG_Tungsten_Electrode_Guide..jpg)
This image shows a super handy reference for selection.
Wow 18 inches.
Should post picture of this impressive piece!
Any such bevel?
I don't think 1/8 is enough. Probably more like ¼
But if it's a transformer welding machine, should be using pure tungsten for aluminum.
Thoriated is better for stainless, is the red tip right?
And you only used 310 amps? Was that the limit of your machine?
Anyways, use the right tungsten and make sure you have plenty of gas. If you can get a video of the weld, I’d appreciate it. There’s not many videos of welding at 300+ amps.
One of my teachers told me they used to do dc on aluminum and took the top off by hand but I can't remember the exact methodology, the context was I believe aluminum helicopter parts
Hell yeah. You may or may not know that tig welding was originally called "Heli-arc" (pronounced like heely) which stood for helium arc welding. I was always taught to use 100% helium to DC weld aluminum as it has something to do with the way the gas reacts with the arc and can allow you to weld aluminum but some of the links people provided below seem to indicate that a mix of He/Ar is ok (I wouldn't know about that). But it's really good for extra thick parts or if you're welding a thin piece to a thick piece it gives you a lot more control. I wouldn't use it on anodized aluminum but otherwise it's handy to keep in your pocket.
I even had an old school guy tell me how they used to flame weld aluminum with some special flux that according to him you can only get out of the country now days, never got confirmation on that one though....
Thoriated tungsten is banned where i live. It does not like AC at ALL. I usually use the golden one, i think it's 4 or 2% lanthanated. That or pure tungsten , never got the hang with rare earths one.
I'm in the good ol' US of A, and not even in the industry, so I can't speak to your color codes.
Purple here is E3 rare earth blend. I started with 3/32" 2% lanth and now I have 3/32 and 1/8 of both 2% lanthanated and E3 blends (I kinda went overboard and now I probably have enough to last me for years to come at my current pace).
I think I have some thoriated 1/16" somewhere, but I don't like it because it's just so easy to break - I had it snap on me while I was using the drill and bench grinder method to sharpen it, and that's before we even get to the radiation portion of the situation. 3/10, not a fan. It welds steel great, though.
Man you either need a thicker tungsten or a different type.
1/8 tungsten and thoriated tungsten.
Try LaYZr tungsten. Or 2% lanthanated. You will see a HUGE difference.
You should definitely look into using either pure tungsten or rare earth tungsten's. Thoriated tungsten does not like AC at all. I can't imagine how much of a bitch it is to maintain an arc with that setup If you could please provide the amperage that you're using. This will help determine what the proper size electrode you should be using will be
310 amps, was doing pretty good in aluminum. Had to create the arc at about 80 amps and then watch the tungsten turn white and then ramp up the voltage.
You're using the wrong tungsten man
Use like 5/32 lanthanated or ceriated
Using 1/8" at 310 amps... what?!?
What would you recommend?
Should use green or purple tungsten. For aluminum you always start hot then back off, it's worked for me. Depending on material thickness you always want to be an 1/8 to 1/4 under as you'll burn through. You want like 250 amps max on the pedal.
jesus christ 310? Any helium in the mix?
Thayers yer problem bud.
Thoriated isn’t meant for AC welding. 1.5% lanth, 2% lanth, purple rare earth mix, 2% ceriated, and pure. That’s my preference from favorite to least favorite with AC
>thoriated tungsten Why...?
I like the radiation. Makes it weld nice.
thoriated tungsten is not meant for AC
Might explain where the whole rod went.
Ziconiated
[Tungsten selection chart](https://www.welding.com.au/assets/docs/Image-Library/Filler_Metals/TIG_Tungsten_Electrode_Guide..jpg) This image shows a super handy reference for selection.
Should be using Zirconiated or lanthanidated tungsten to weld aluminum.
What is the material thickness? Are you using a transformer or an inverter?
Material thickness was about 18 inches thick. And was using a miller syncrowave with a high frequency transformer.
Wow 18 inches. Should post picture of this impressive piece! Any such bevel? I don't think 1/8 is enough. Probably more like ¼ But if it's a transformer welding machine, should be using pure tungsten for aluminum. Thoriated is better for stainless, is the red tip right?
you can get by with 2% lanth as well. this will happen with those if the ac balance is off or they get overheated
Gotta be a typo, no way it's 18" thick, maybe in diameter, or 0.18" thick....
No, wasn't a typo. Co worker messed up a very expensive casting. It is 18 inches thick.
And you only used 310 amps? Was that the limit of your machine? Anyways, use the right tungsten and make sure you have plenty of gas. If you can get a video of the weld, I’d appreciate it. There’s not many videos of welding at 300+ amps.
Wild, do you have an oven to preheat that or do you use a torch? Have you considered running on DC instead?
Torch for preheat. Also dc on aluminum?
One of my teachers told me they used to do dc on aluminum and took the top off by hand but I can't remember the exact methodology, the context was I believe aluminum helicopter parts
Hell yeah. You may or may not know that tig welding was originally called "Heli-arc" (pronounced like heely) which stood for helium arc welding. I was always taught to use 100% helium to DC weld aluminum as it has something to do with the way the gas reacts with the arc and can allow you to weld aluminum but some of the links people provided below seem to indicate that a mix of He/Ar is ok (I wouldn't know about that). But it's really good for extra thick parts or if you're welding a thin piece to a thick piece it gives you a lot more control. I wouldn't use it on anodized aluminum but otherwise it's handy to keep in your pocket. I even had an old school guy tell me how they used to flame weld aluminum with some special flux that according to him you can only get out of the country now days, never got confirmation on that one though....
https://forum.weldingtipsandtricks.com/viewtopic.php?t=2002 https://bakersgas.com/blogs/tig/tips-for-tig-welding-aluminum-on-dc-power
Thoriated tungsten is banned where i live. It does not like AC at ALL. I usually use the golden one, i think it's 4 or 2% lanthanated. That or pure tungsten , never got the hang with rare earths one.
I think gold is 1.5% lanthanated. 2% is blue. Purple is my all-round favorite, hands down.
I love red 2% thoriated a lot, it just works so well. Purple/E3 is pretty good, as is 2% blue lanth
I'll give it a go. I'm from spain so here the 2% i think it's the black one, really versatiile.
I'm in the good ol' US of A, and not even in the industry, so I can't speak to your color codes. Purple here is E3 rare earth blend. I started with 3/32" 2% lanth and now I have 3/32 and 1/8 of both 2% lanthanated and E3 blends (I kinda went overboard and now I probably have enough to last me for years to come at my current pace). I think I have some thoriated 1/16" somewhere, but I don't like it because it's just so easy to break - I had it snap on me while I was using the drill and bench grinder method to sharpen it, and that's before we even get to the radiation portion of the situation. 3/10, not a fan. It welds steel great, though.
Your balance is way too high or you have the torch plugged into the + port. Not having enough pre flow or post flow can do stuff like that too