HMMM Need help Contamination Aluminum

[nissan20det]

Hey guys I'm in a pickle here! Im welding chromoly for the first time and that well actually other than when i weld it it gives off a awkward smell and I just mention this to see if this related to my problem. Now first thing is the fact that im getting horrible contamination when welding aluminum. So far what I have done...Checked for Leaks (argon) , made sure tank is argon, tried 3 different tugstens(2 2% Lanth-1 Pure), tried diff. filler rod (new bag of 4043. changed collet and body(using screened collet body), used 6 7 8 9 cups, turned cleaning action up to the point of tungsten melting, tried gas flow to point of arc blowing out and down to no gas, also tried 4 different pieces of stock all 6061 t65 mill stock fresh and clean. So this is weird i had my machine dialed in and changed nothing before all this trial and error. since this worked great the only thing I have changed is I exchanged my argon tank for a new one. now it has to be tank in my eyes it worked fine just before so am i wrong? What else could it be? does anything happen tanks that could cause peppering, contamination? thanks zach

[ja baudin]

Hey guys I'm in a pickle here! Im welding chromoly for the first time and that well actually other than when i weld it it gives off a awkward smell and I just mention this to see if this related to my problem. Now first thing is the fact that im getting horrible contamination when welding aluminum. So far what I have done...Checked for Leaks (argon) , made sure tank is argon, tried 3 different tugstens(2 2% Lanth-1 Pure), tried diff. filler rod (new bag of 4043. changed collet and body(using screened collet body), used 6 7 8 9 cups, turned cleaning action up to the point of tungsten melting, tried gas flow to point of arc blowing out and down to no gas, also tried 4 different pieces of stock all 6061 t65 mill stock fresh and clean. So this is weird i had my machine dialed in and changed nothing before all this trial and error. since this worked great the only thing I have changed is I exchanged my argon tank for a new one. now it has to be tank in my eyes it worked fine just before so am i wrong? What else could it be? does anything happen tanks that could cause peppering, contamination? thanks zach

Are you welding on AC not DC.

[H80N]

Pics.. Settings.. Machine...???

Hey guys I'm in a pickle here! Im welding chromoly for the first time and that well actually other than when i weld it it gives off a awkward smell and I just mention this to see if this related to my problem. Now first thing is the fact that im getting horrible contamination when welding aluminum. So far what I have done...Checked for Leaks (argon) , made sure tank is argon, tried 3 different tugstens(2 2% Lanth-1 Pure), tried diff. filler rod (new bag of 4043. changed collet and body(using screened collet body), used 6 7 8 9 cups, turned cleaning action up to the point of tungsten melting, tried gas flow to point of arc blowing out and down to no gas, also tried 4 different pieces of stock all 6061 t65 mill stock fresh and clean. So this is weird i had my machine dialed in and changed nothing before all this trial and error. since this worked great the only thing I have changed is I exchanged my argon tank for a new one. now it has to be tank in my eyes it worked fine just before so am i wrong? What else could it be? does anything happen tanks that could cause peppering, contamination? thanks zach

What type of machine..?? settings..??

weld pics..??

what type of aluminum are you welding?? thickness?? (you said 6061 is it marked??)

How do you think this relates to chrome moly..??.. smell??

Have you looked here..?? look familiar..?? peppering..??

http://www.millerwelds.com/resources/articles/common-TIG-GTAW-welding-problems-visual-guide-graphic

http://www.millerwelds.com/resources/tech_tips/TIG_tips/troubleshooting.html

[nissan20det]

Okay I forgot to say that, yes I'm on AC with ground POS and torch NEG.

Yes I did check those pages out that what lead me to the tank...

Heres some pics, so there's two with bad bad peppering and one pic from before I changed the tank.

[nissan20det]

So these are just scrap pieces be the third pic has no contamination?? The Metal is Labeled 6061 t65 and it is clean. Could this be the tank?? I think its related cuz i now get that smell with mild and stainless steel which i never did before...

[H80N]

Welder brand..?? model??

settings..?? ac balance..?? frequency??

physically clean the aluminum with dedicated wire brush or abrasive just before welding??

acetone wipe??

tungsten stickout..?? size..??

argon flow cfh??.... backcap o-ring ok..??

[Broccoli1]

Go with your first gut reaction- the only thing you changed was a new jug of gas. take it back and try a new jug.
Bad jugs of argon do happen.

[nissan20det]

Welder brand..?? model?? settings..?? ac balance..?? frequency?? physically clean the aluminum with dedicated wire brush or abrasive just before welding?? acetone wipe?? tungsten stickout..?? size..?? argon flow cfh??.... backcap o-ring ok..??

Luxor Ebay 200p and I love It Using pedal, pulse off, Ac balance I always use at about 40% electrode Pos and tried As high as i could go till tungten was melting off no difference, Fixed 60HZ, Stainless brush ONLY for Alum(even bought new one), yes tried acetone wipe, tungsten 3/16 2% Lanth. at 3/16-1/4 past cup, Yes Tungsten cover oring brand new (also did Bubble Leak down test no leaks), argon flow I tried to point of arc blow out and down to no gas(as I increased I just had turbulence no change in Bead quality) Im telling you this was a day to day change old bottle fine new one problems??

[H80N]

Luxor Ebay 200p and I love It Using pedal, pulse off, Ac balance I always use at about 40% electrode Pos and tried As high as i could go till tungten was melting off no difference, Fixed 60HZ, Stainless brush ONLY for Alum(even bought new one), yes tried acetone wipe, tungsten 3/16 2% Lanth. at 3/16-1/4 past cup, Yes Tungsten cover oring brand new (also did Bubble Leak down test no leaks), argon flow I tried to point of arc blow out and down to no gas(as I increased I just had turbulence no change in Bead quality) Im telling you this was a day to day change old bottle fine new one problems??

Argon... try about 15 cfh.... is the air in the shop still or do you have breezes??

set your balance to 70% negative raise your amperage and move faster...

Tungsten prep?? ground to taper and blunted??

Broc may very well be right about a bad bottle of gas... it does happen... not often in my experience... but you may have drawn the lucky ticket... you might try trading it..

but usually it turns out to be operator related..

[nissan20det]

Okay guys I figured it out!!!! If was the bottle for sure... Hit up high plains welding(Denver CO supply store) and said it getting bad bad contamination and a funny smell they said "well can you stop by today to swap her out". I was shocked lol they took that well... So I got there said I was the guy on the phone and I asked is this a common thing to happen, are you convinced it's the tank as well and the said that it's not common (didn't think so) but the said that diff. Your problem. I asked how they new and it's that funny smell I slightly mentioned. He said that's the signs of a bad bottle. Turns out I was the first person to use it since it's new test date certification so they think some of the purging chemicals for X-ray where most likely left behind.... Crazy.

Well lol I hope my experience helps other people out... If you changed nothing but your bottle and you do your dumb dumb check list and all things check out check for a funny smell ON mild steel, stainless steel, or chromoly and your aluminum is dirty as all **** ..... BOTTLE!!!!!!!


Thanks for all the help guys! Truly appreciate it!

pics.... Some stainless and aluminum with new bottle one pic has all my peppered welds with one bead on it with the new bottle

[H80N]

Glad you got it sorted out...

[nissan20det]

Thanks Again, Ya so I always used the 10N series collet body and I just picked up the medium screened gas lens and WOW!!!!! what a difference in coloration with stainless its unbelievable! If anyone is having troubles with that beautiful coloration of stainless and just cant quite get it. Change from 10N collet to screened gas lens you wont regret it I promise! Have you guys heard of using L310 filler with 4130 chromoly? I know ER70S-2 is the best for not preheating or annealing and ER80S-D2 if you do so, but 310 I heard some people says it works great. does anyone know what tinsel strength 310 has? or had experience with 310?

[H80N]

Thanks Again, Ya so I always used the 10N series collet body and I just picked up the medium screened gas lens and WOW!!!!! what a difference in coloration with stainless its unbelievable! If anyone is having troubles with that beautiful coloration of stainless and just cant quite get it. Change from 10N collet to screened gas lens you wont regret it I promise! Have you guys heard of using L310 filler with 4130 chromoly? I know ER70S-2 is the best for not preheating or annealing and ER80S-D2 if you do so, but 310 I heard some people says it works great. does anyone know what tinsel strength 310 has? or had experience with 310?

Why fool around with proven tested filler applications... when that experimentation could result in a substandard weld and possible injury or death..??

using stainless as a filler for 4130 was a fad about 30 years ago in some racing circles...(I did some of that myself)

I will stick with the proven safe fillers ER70S-2 & ER80S-D2

Here is an AWS article that covers it

http://www.aws.org/wj/apr03/AWfeature.html

[nissan20det]

Yup true that! ill stick with 70S-2 What grade stainless to you start using 316L rod on and Aluminum i was told 4043 is good up to 6061 T65? at what point do you move to 5356?

[H80N]

Yup true that! ill stick with 70S-2 What grade stainless to you start using 316L rod on and Aluminum i was told 4043 is good up to 6061 T65? at what point do you move to 5356?

Stainless steel TIG filler selection

here is a selection chart

http://www.weld.com/files/Stainless_Steel_Welding_Filler_Metal_Selection_Chart.pdf

For Aluminum 4943 covers all of the places you would use 4043 and a bunch more
here is a thread you might want to read..

http://www.millerwelds.com/resources/communities/mboard/showthread.php?31961-4943-for-356-Aluminum-TIG-Casting-repair&highlight=4943