Fronius 320i mig welding 0.8mm aluminium wire burn back & bird nesting in back 7

[Muhammad Jami Raza]

I am trying to weld 0.8mm Aluminium wire with fronius tps 320i,every time i try to weld my tip get burned and bird nesting occurs at the back, my settings are according to weldconnect application which describes 2.1mm material thickness,10m/min wire feed, 85amps current with synergic pulse welding process, there are two more process namely ARC LENGHT CORRECTION & PULSE/DYNAMIC CORRECTION I AM NOT FAMILIAR WITH THEM PLEASE HELP ME WITH THIS I BEEN TRYING FOR TWO DAYS.
THANK YOU VERY MUCH

 

[weldstan]

Do you have a dual feed system - one at the torch and one at spool? If not you will need one.

 

First, with that small aluminium wire diameter and high feed speed you need a push-pull wire feeder.
Second, call in the equipment vendor for tech support. Or retain an actual Welding Engineer experienced in aluminium.
Third, do not use Fronius equipment if you have the choice.


"Everyone is entitled to their own opinions, but they are not entitled to their own facts."

 

[Muhammad Jami Raza]

weldstan no ı dont have dual feed torch just one comıng from machıne

 

[Muhammad Jami Raza]

ıronıc metallurgıst ı couldnt even start weldıng ıt just burnoff at the very fırst weld

 

[kingnero]

weldstan and ironic metallurgist mean a spoolgun, not a dual wire feeder. Which is a good idea, especially with longer cable runs from wire feeder to torch, thin wire and (soft) type 4 filler (4043, 4047).

Arc length correction (-10 ... +10) will slightly decrease/increase the voltage, giving a shorter/longer arc.
Dynamic correction (-10 ... +10) will only work during pulse mode (affecting the droplet formation at peak current).

If your wire burns during starting, likely your start current is too high. Should be no more than 110 - 120 % of your welding current.
Adjust the start current time (in sec.) accordingly.
I have no experience with wire feed speed/current relationship of 0.8 mm Al wire, however I think 10m/min might be a bit high if you're aiming for 85A.
There is also a start arc length correction if I'm not mistaken. I'd leave that alone (-10 ... +10 => leave at 0)
Another possibility is that you have a very aggressive upslope.

Also, you you have SFI (spat free something) on your machine? There is also a hotstart function that comes with SFI, I'd turn that off also.

@ IM, why would you advice against fronius? I've worked more with their GTAW sources, however I haven't heard any complaints from welders that use fronius on a day by day basis... I'd position them in the top 10 of welding sources.

 

[Muhammad Jami Raza]

thnak you very much kingnero for your time i will again for the settings, is there any chance that i can contact you easily

 

kingnero,
Because their strategy for pulsing control is to mechanically modulate the wire feed speed, a really bad idea. I've heard complaints of wire feeders burning out in one years time. Lincoln STT and Miller RMD have it right - they control the waveform digitally.
(Besides, and any welding company that markets its technology with the term 'cold metal transfer' makes me laugh - I prefer my metal transfer to be hot, very hot.)

"Everyone is entitled to their own opinions, but they are not entitled to their own facts."

 

Why are we trying to troubleshoot from a distance a piece of high tech equipment in the hands of a struggling user who is not a welder, technician or welding engineer?

"Everyone is entitled to their own opinions, but they are not entitled to their own facts."

 

[weldstan]

We only used the Lincoln and Miller systems together with a spool gun for Al GMAW welding in the field. The OP has no chance of success with the system as currently employed that he is using with the small diameter Al alloy wire.

 

[kingnero]

Because their strategy for pulsing control is to mechanically modulate the wire feed speed

Didn't know that - that sounds sketchy indeed. I do consider their GTAW machines top notch.


As for your other question, honestly right now because I'm bored due to the lockdown in our area... Doesn't mean you're not right, though.

 

[Muhammad Jami Raza]

 

[Muhammad Jami Raza]

 

[Muhammad Jami Raza]

okay so these are the parameter for 0.8mm almg5 wire

 

[kingnero]

So you are pulse welding (I didn't catch that in your opening post), using a mechanically monitored/driven pulsed wire feed system (that I didn't know about).
Now I have no idea how that would work with a push/pull system or spoolgun, but now I understand (and concur with) IM's remark to stay away from the fronius MIG/MAG welding machines.

The settings that are on the screen look good, however there's an ignition current of 500 A, that sure looks suspicious, and I'm not too fond of the 2.6 Hz. Incredibly annoying for the welder.

Can you try, in no particular order:
- changing the 500A ignition current, but I'm not too sure what that does in manual mode?
- a bigger wire (together with the correct drive rolls, liner, contact tip (eg. 1.2A for aluminium!),
- not pulsed welding (so a continuous feed of the wire),
- a spool gun (also known as push pull system), as suggested above,
- another welding machine, as suggested above,
- a torch with an as short as possible cable run (max. 10 ft/3m, preferably shorter)
- Showing a picture of the "free" wire run between the drive rolls and the entrance of the liner/torch cables (= the place where the birdnesting happens)

 

[Muhammad Jami Raza]

kingnero ı am stuck wıth fronıus due to company order ı have to master thıs machıne wıth 0.8 mm wıre and start to weld chassıs

 

[Muhammad Jami Raza]

 

[kingnero]

OK, so start with what you can change...

For what it's worth, the set-up of the drive rolls looks good from here.

 

[IFRs]

Will it drive the wire without creating an arc? In other words is this a drive failure?
What gas are you using, at what flow rate?
Does the gas come on first?
What is the polarity of your setup: is + or - to the torch?
Are the drive wheels and liner the correct ones for your wire diameter?
Is the wire brand new or has it been sitting outside in the rain for weeks?
How far away from the work is your torch?
Where is the end of the tip relative to the end of the cup/

 

[CWEng]

Are you using a teflon coated liner for welding aluminim? They can help the wire feeding quite a bit. Assuming your issue is really wire feeding, not parameters, then use what Kingnero said: - a torch with an as short as possible cable run (max. 10 ft/3m, preferably shorter)

If that doesn't work, it appears Fronius does make a push-pull gun, which is what you would need.

Also, increase your wire diameter if you can. A larger wire will be a lot stiffer.