Aluminum welders

Anonymous-0 · Feb 24, 2013

Made my first project out of aluminum yesterday. Got it welded together, doesn't look very good, but I think it will hold. It's just a rack on the four wheeler to hold a tagging box and a few other things that we use while on the 4-wheeler, so it is not a life or death experience if it fails. My question, there was a tremendous amount of black soot around all the welds. Did I not have the aluminum clean enough, or is there some other problem? It was all new, and I brushed it good with a stainless steel brush.

jon f mn · Feb 24, 2013

What did you use to weld it?

Janicholson · Feb 24, 2013

Argon inert gas flow was not sufficient to provide an envelope at the weld arc. Jim

John B. · Feb 24, 2013

Are you welding with flux core wire or using argon 25/75? Is it a wire feed welder?

Most people don't know but when you weld aluminum with argon you go the opposite direction than you would when stick welding. You want the gas to blow away the atmosphere in front of where you're going be welding. You point your wire away from your bead or what you just welded but yet keep it in the puddle. This is what we were taught 35 years ago. It's always worked for me.

Anonymous-0 · Feb 24, 2013

Ya, I think that's the first question. LoL Was it MIG welded or TIG welded or stick welded? If aluminum gets black around the weld is because it is either dirty and/or contaminated. You use straight argon for MIG or TIG on aluminum and the metal has to be really clean. Sometimes when doing aluminum repairs, especially on cast aluminum, it's not uncommon to have to weld it, grind it out and weld it again to get rid of all the dirt/contamination. A contaminated tungsten can cause problems too. MIG requires a push technique. A stainless steel brush can be used but it has to be a new brush only used on aluminum. If it was used on any steel will pick up carbon and contaminate the aluminum.

Chris(WA) · Feb 24, 2013

You use pure 100% Argon for the cover gas with aluminum. Black means lack of cover gas. Line was not purged or too low flow rate.

Anonymous-0 · Feb 24, 2013

Sorry that I didn't give enough info. I'm using a wire feed welder and 100% Argon. 0.35 wire and I was welding 1"x 1/8" angle. Can you weld aluminum with a stick welder? What kind of rod would be needed, if possible?

Anonymous-0 · Feb 24, 2013

I tried going both ways, it didn't seem to make any difference. I know it will take a lot of practice, but when I bought the welder they had a demonstration piece to weld. Off course that welded like a dream! Now to get it set correctly so I can do it again!

Anonymous-0 · Feb 24, 2013

They make rods for stick welding aluminum but your MIG is a MUCH, MUCH better choice. Most people consider the stick rods a waste of time. What wire are you using? 4043 usually welds easier than 5356. I don't know what machine you're using but you could try preheating the aluminum a little if your machine isn't hot enough. There is also a slight possibility that your argon is contaminated. It's not common but we've had a couple bad argon cylinders in the last couple of months. Mostly noticeable doing aluminum TIG yet hardly noticeable welding steel. If you tried everything else and still get black welds, consider it could be contaminated argon. Your supplier should replace the cylinder if you just recently picked it up for your aluminum project.

Brad Buchanan · Feb 24, 2013

I am far from an expert but I have found that I have better luck when I preheat the pieces before welding.

Brad

jon f mn · Feb 24, 2013

If you used 5356 wire that will leave a LOT more black soot than 4043. If you have one of those little wire feeds and are pushing the wire down the gun you may need to stick to 5356 or it won't push. Do you have a plastic liner in the gun if that's what you are using? You would be taxing the power on one of those small welders on 1/8 inch alum. so you could try preheating it with a torch as stick said. I doubt that contamination is your problem.

oliver power · Feb 24, 2013

I read all kinds of different "Do's & don't's" when it comes to welding aluminum. Having clean, uncontaminated aluminum is one I hear / read the most of. Yet, the man who welds my aluminum projects simply tig welds the pieces together, as if it were carbon steel. I've brought him aluminum that's snow covered, cold, wet, dirty, you name it. A quick wipe with rag. Maybe knock off some heavier dirt with wire brush, and weld her up. Best aluminum welds I've ever seen! Quite often, people in public look at my aluminum scaffold equipment. Most every time, they ask Who Did The Welding?, And comment on the nice welds. So, although I agree with everything mentioned, I know it has more to do with technique, settings, and experience.His tig welder is a water cooled Randsom, Ransond, or something like that. In other words, it's not a high end Miller.

jon f mn · Feb 24, 2013

I used to get a couple of tanks a year where the gas company accidentally put mix in an argon tank, so that could very well be his problem. I would like to see a pick of his welder and what he did tho. It's hard to diagnose a problem with those descriptions.

Anonymous-0 · Feb 25, 2013

The best we could figure was the cylinders were re-certified and not properly purged before filling them or someone wasn't paying attention when filling them. Pictures would help.

Travis M · Feb 25, 2013

turn the gas up

Anonymous-0 · Feb 25, 2013

How much pressure should I be using? 100% Argon.

Travis M · Feb 25, 2013

I I think we are around 25 psI. We jump up from 20 to 25 and it helped a bunch

jon f mn · Feb 25, 2013

Post pics if posible. Its hard to say what your problem is otherwise. You could chase this forever with just guessed for advice.

Anonymous-0 · Feb 25, 2013

It's not PSI, the gauge or flow meter should read in CFH. Around 25 CFH should be good. Too much gas flow can cause problems too.

Anonymous-0 · Feb 25, 2013

I don't know how to post pictures on here. To those who tried to give helpful advice, thank you. Will try some of the suggestions and see if I can get it figured out.

Aluminum welders

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