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Porosity issues with 6061-T6 aluminum

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  • Porosity issues with 6061-T6 aluminum

    We're having a problem with porosity in our 4027 aluminum 3G coupons. We test on .040 and .063 3G, pre weld cleaning is acetone wipe, ss wire brush with new brush and acetone wipe after, rubber gloves to handle coupons. We clean both coupons and welding wire and use pure argon. Would adding some helium help?

  • #2
    Originally posted by GDKelley View Post
    ...We ... use pure argon. Would adding some helium help?
    First, what is your flow rate and other settings? How is your travel speed and ability to watch the puddle? Are you already familiar enough with welding steel without issues?


    • #3
      To answer your question.....I would not expect adding helium to help reduce your porosity issues. I believe Mac to be asking more appropriate questions that would be related to porosity.

      Something is corrupt, be it the base metal, the cleaning solution, the shielding gas, the tungsten or the technique.

      Don’t leave any details out. Is this a new problem? Is the gas cylinder new? Is the operator new? Have you tried changing your consumables including the torch?

      Happen to have some pictures you can post up? Might give us an idea of the origin of your problems.

      I am confident we can help solve this porosity problem.


      • #4
        I'll get all the settings from the welders that are having problems Monday. Myself along with 99% of our welders are D17.1 certified on 5 alloys. It's looking like it's probably equipment or technique as two other welders just passed x-ray on their .040 aluminum today first attempt. The two guys having trouble have successfully passed aluminum 3G on .063, but they are newer welders.


        • #5
          I'm starting to suspect they are pulling their welding rod out of the gas coverage, could that be the problem?


          • #6
            Yes, if you pull the rod out while it's still hot, it turns to slag, which you then add to the puddle next time you dip it.