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Tig Welding 1" Thick Alum. ( 6061 )

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  • Tig Welding 1" Thick Alum. ( 6061 )

    I use a Hobart 300 S Cyber-Wave Tig, I need to weld a 1" alum Box. 16" sq. inside & out. The box does have acsess holes to weld the inside. I normally use a #20 Torch, I've tried switch'n to a #18 Torch w/ Argon, ( no good ) I tried Argon/Helium mix, ( no good ) there's alot of contamination, I think the Machinist used a cleaner or maybe a cutting fluid to fab the parts and did'nt clean it enough, I don't know. maybe the Machine is uncapable.
    Any suggestions ?

  • #2
    Originally posted by Ed Shuba View Post
    I use a Hobart 300 S Cyber-Wave Tig, I need to weld a 1" alum Box. 16" sq. inside & out. The box does have acsess holes to weld the inside. I normally use a #20 Torch, I've tried switch'n to a #18 Torch w/ Argon, ( no good ) I tried Argon/Helium mix, ( no good ) there's alot of contamination, I think the Machinist used a cleaner or maybe a cutting fluid to fab the parts and did'nt clean it enough, I don't know. maybe the Machine is uncapable.
    Any suggestions ?
    You need a LOT more horsepower to TIG Weld it..... something like a Dynasty 700...

    http://www.millerwelds.com/pdf/spec_sheets/AD5-0.pdf

    you might be able to get by... with TONS of preheat... but think you just do not have enough horsepower... and a 20 series torch will melt down like a candle in the sun before you will do any good on that large a chunk of one inch... don't think a helium mix will make up for the lack of horsepower either...

    maybe somebody else has a better answer for you... but that is how it looks from here..
    Last edited by H80N; 07-12-2012, 10:25 PM.
    .

    *******************************************
    The more you know, The better you know, How little you know

    “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

    Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

    My Blue Stuff:
    Dynasty 350DX Tigrunner
    Dynasty 200DX
    Millermatic 350P w/25ft Alumapro & 30A
    Millermatic 200

    TONS of Non-Blue Equip, plus CNC Mill, Lathes & a Plasmacam w/ PowerMax-1000

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    • #3
      You need a bigger machine. 1/2" takes a 300 amp machine. I personally would mig weld it.

      Comment


      • #4
        I would mig it with preheat. What grade aluminum is it? Is it assembled or individual pcs. you can clean. If you can clean each pc. then do it to remove any machining coolant that has dried on it. If it is an assembly then you will need to clean as best you can & pre-heat also. You are peeing in the wind with your set up.
        MM250
        Trailblazer 250g
        22a feeder
        Lincoln ac/dc 225
        Victor O/A
        MM200 black face
        Whitney 30 ton hydraulic punch
        Lown 1/8x 36" power roller
        Arco roto-phase model M
        Vectrax 7x12 band saw
        Miller spectrum 875
        30a spoolgun w/wc-24
        Syncrowave 250
        RCCS-14

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        • #5
          200 amps on 1/4 inch aluminum is about where I start. You REALLY should consider mig process. Me personally, anything over a quarter gets mig.
          welder_one

          nothing fancy, just a few hot glue guns for metal
          www.sicfabrications.com

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          • #6
            I have owned many Cyberwave300s in the past. Great 3 phase tig welder.
            Pics would help, but there is no question you can do this, as I have done many times in the past. Your machine is a monster. I liked them better than Aerowaves. But alas I killed them all off.

            1. Determine your setup is working correctly. Make sure your balance is at 6 or 7 from what I remember, and I found if arc force is not midway, it welds irregular. Have you had your Cyberwave syncronized lately? Mine had to be done every 400 to 500 hours, or twice a year, and cost about $300. If not it rectified horribly. Make sure you set to max penetration, not cleaning.

            2. Preheat in whatever manner available to you to approx 250, to 350F.

            3. Bevel the outside joints, run a root pass and then cover pass. Then move to the inside immediatly before you loose your heat.

            4. Use 75%argon/25%helium. Helium helps a ton.

            My guess is you have a gas problem right off. If you suspect surface contamination, clean it yourself.

            You could certainly weld it DC straight with pure Helium, but that would be last resort.

            Lastly I believe you have a gas problem. I should at least arc clean.
            Nothing welded, Nothing gained

            Miller Dynasty700DX
            3 ea. Miller Dynasty350DX
            Miller Dynasty200DX
            ThermalArc 400 GTSW
            MillerMatic350P
            MillerMatic200 with spoolgun
            MKCobraMig260
            Lincoln SP-170T
            Linde UCC305 (sold 2011)
            Hypertherm 1250
            Hypertherm 800
            PlasmaCam CNC cutter
            Fadal Toolroom CNC Mill
            SiberHegner CNC Mill
            2 ea. Bridgeport
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            Doringer 14" Cold Saw
            6 foot x 12 foot Mojave granite

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            • #7
              Originally posted by shovelon View Post
              I have owned many Cyberwave300s in the past. Great 3 phase tig welder.
              Pics would help, but there is no question you can do this, as I have done many times in the past. Your machine is a monster. I liked them better than Aerowaves. But alas I killed them all off.

              1. Determine your setup is working correctly. Make sure your balance is at 6 or 7 from what I remember, and I found if arc force is not midway, it welds irregular. Have you had your Cyberwave syncronized lately? Mine had to be done every 400 to 500 hours, or twice a year, and cost about $300. If not it rectified horribly. Make sure you set to max penetration, not cleaning.

              2. Preheat in whatever manner available to you to approx 250, to 350F.

              3. Bevel the outside joints, run a root pass and then cover pass. Then move to the inside immediatly before you loose your heat.

              4. Use 75%argon/25%helium. Helium helps a ton.

              My guess is you have a gas problem right off. If you suspect surface contamination, clean it yourself.

              You could certainly weld it DC straight with pure Helium, but that would be last resort.

              Lastly I believe you have a gas problem. I should at least arc clean.
              If Shovelon says that machine has enough grunt , with preheat and Helium... then it must be doable....

              good luck and keep us posted...
              .

              *******************************************
              The more you know, The better you know, How little you know

              “The bitterness of poor quality remains long after the sweetness of low price is forgotten”

              Buy the best tools you can afford.. Learn to use them to the best of your ability.. and take care of them...

              My Blue Stuff:
              Dynasty 350DX Tigrunner
              Dynasty 200DX
              Millermatic 350P w/25ft Alumapro & 30A
              Millermatic 200

              TONS of Non-Blue Equip, plus CNC Mill, Lathes & a Plasmacam w/ PowerMax-1000

              Comment


              • #8
                I don't know what the duty cycle on that machine is but hopefully 100% at max. You will need a big watercooled torch. There comes a time when maybe you can struggle through something but it would be smarter to let someone with the right equipment do it. How long do you think it will take to tig weld this? You have 16 feet of weld on 1" plate to do. This wil take muliple passes so your looking at a lot of linear feet. Get really good gloves because your hands will get hot especially welding the inside. I really don't know how you can tig this & be profitable. Just my opinion.
                MM250
                Trailblazer 250g
                22a feeder
                Lincoln ac/dc 225
                Victor O/A
                MM200 black face
                Whitney 30 ton hydraulic punch
                Lown 1/8x 36" power roller
                Arco roto-phase model M
                Vectrax 7x12 band saw
                Miller spectrum 875
                30a spoolgun w/wc-24
                Syncrowave 250
                RCCS-14

                Comment


                • #9
                  Originally posted by MMW View Post
                  I don't know what the duty cycle on that machine is but hopefully 100% at max. You will need a big watercooled torch. There comes a time when maybe you can struggle through something but it would be smarter to let someone with the right equipment do it. How long do you think it will take to tig weld this? You have 16 feet of weld on 1" plate to do. This wil take muliple passes so your looking at a lot of linear feet. Get really good gloves because your hands will get hot especially welding the inside. I really don't know how you can tig this & be profitable. Just my opinion.
                  I have not seen a pic yet, but I know I could do it.

                  But I think there is a gas issue still.
                  Nothing welded, Nothing gained

                  Miller Dynasty700DX
                  3 ea. Miller Dynasty350DX
                  Miller Dynasty200DX
                  ThermalArc 400 GTSW
                  MillerMatic350P
                  MillerMatic200 with spoolgun
                  MKCobraMig260
                  Lincoln SP-170T
                  Linde UCC305 (sold 2011)
                  Hypertherm 1250
                  Hypertherm 800
                  PlasmaCam CNC cutter
                  Fadal Toolroom CNC Mill
                  SiberHegner CNC Mill
                  2 ea. Bridgeport
                  LeBlond 15" Lathe
                  Haberle 18" Cold Saw
                  Doringer 14" Cold Saw
                  6 foot x 12 foot Mojave granite

                  Comment

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