Q. I HAVE A SYNCROWAVE 180 SD TIG/STICK . MY QUESTION IS, I FOUND IT VERY DIFFICULT TO MAKE A SMALL BEAD WHEN WELDING ALUMINUM. IT IS ESPECIALLY DIFFICULT WHEN WELDING IN CORNERS. THE BEADS LOOK GREAT AND EVERYTHING TIES IN WELL, BUT THEY ARE JUST LARGE. PLEASE HELP!!! (Submitted by: CHRIS BOUNDS from SOUTH PICAYUNE MS)
A. Depending on the thickness of the Aluminum you are working with, you may be able to try a smaller tungsten. Or you may try a Zirconiated, Ceriated, or Lanthanated tungsten. These will handle larger weld currents with a smaller tungsten. I would then extend the tungsten closer to the inside corner joint to keep the arc length to a minimum. Unfortunately the frequency of the AC output will also determine the bead width. Only the Dynasty and the Aerowave have variable output frequency. The higher the frequency, the tighter the bead will be.