Since my last post on this subject I have still not been able to butt-weld thin 2024-T3 Aluminum to my satisfaction. So I put in a call to the Miller Tech deptartment and had a talk with Don. His advise was excellent and since it was a bit unorthodox, I want to pass this info along to the group.
As I mentioned in earlier posts (August 3, 2004) I was having a hard time keeping the edges of the aluminum from melting away when welding thin edge-to-edge pieces with 1/16" pure tungsten electrode balled on the end in the normal fashion. My machine is a new Syncrowave 180SD. The problem turns out to be the arc was wandering and I was unable to control it's travel. It seemed to be jumping from one side of the butt to the other.
Don's recommendation was to try 2% Thoriated rod...... and it worked to perfection !!! It takes patience and practice but at least I can now butt- weld thin 2024-T3 passibly.
Here are the machine settings
1) Soft Start setting
2) 1/16" AL rod 5356
3) 1/16" - 2% Thoriated rod - (red)...yes this is normally used for steel.
4) 3/8" Gas cup
5) 100% Argon -- 18lbs CFH scale
6) AC @ 18-20 Amps
7) Clean AL material w/Acetone and use SS brushing if necessary
8) Butt the materials to be welded as closely as possible - with my limited experience, I would consider 1/16" or more gap to be excessive.
Preparing the Tungsten ( Yes, it's 2% Thoriated)
Grind to a point ----just as you would do for steel welding.
That's it and I hope this has been of some help.
Tom Warren
Hartwell, GA
As I mentioned in earlier posts (August 3, 2004) I was having a hard time keeping the edges of the aluminum from melting away when welding thin edge-to-edge pieces with 1/16" pure tungsten electrode balled on the end in the normal fashion. My machine is a new Syncrowave 180SD. The problem turns out to be the arc was wandering and I was unable to control it's travel. It seemed to be jumping from one side of the butt to the other.
Don's recommendation was to try 2% Thoriated rod...... and it worked to perfection !!! It takes patience and practice but at least I can now butt- weld thin 2024-T3 passibly.
Here are the machine settings
1) Soft Start setting
2) 1/16" AL rod 5356
3) 1/16" - 2% Thoriated rod - (red)...yes this is normally used for steel.
4) 3/8" Gas cup
5) 100% Argon -- 18lbs CFH scale
6) AC @ 18-20 Amps
7) Clean AL material w/Acetone and use SS brushing if necessary
8) Butt the materials to be welded as closely as possible - with my limited experience, I would consider 1/16" or more gap to be excessive.
Preparing the Tungsten ( Yes, it's 2% Thoriated)
Grind to a point ----just as you would do for steel welding.
That's it and I hope this has been of some help.
Tom Warren
Hartwell, GA
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