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

 

[Muhammad Jami Raza]

IFRs yeah the drive rollers are new,
argon gas 10 l/min aveerage
yeah pre flow gas come first
AC aluminium i am using
liners and drive rolls are perfect in size with 0.8mm 5356 Al wire
wire is brand new
not so far my torch is and its always kept straight

 

[Muhammad Jami Raza]

CWEng yeah i am using fronius teflon liner for aluminium
ı cant increase the diameter due to given task

 

[Muhammad Jami Raza]

can anyone explain me all the parameters which i have upload in pictures please

 

[kingnero]

Have you tried those yet?

- changing the 500A ignition current, but I'm not too sure what that does in manual mode?
- not pulsed welding (so a continuous feed of the wire)

 

[Muhammad Jami Raza]

What is ARC LENGTH CORRECTION
PULSE/DYNAMIC CORRECTION
START ARC LENGTH
END ARC LENGTH
END CURRENT TIME
SFI
SFI HOT START
WIRE RETRACT
HOW MUCH PENETRATION STABILIZER SHOULD BE
HOW MUCH ARC LENGTH STABILIZER SHOULD BE
DELTA WIRE SPEED
ARC LENGTH CORRECTION HIGH
ARC LENGTH CORRECTION LOW

 

[Muhammad Jami Raza]

YEAH KINGNERO ı trıed everythıng you saıd

 

[kingnero]

with what result?

 

[Muhammad Jami Raza]

wıre burn at the tıp

 

[kingnero]

Can't help you then. Get someone around who is physically there. You can't troubleshoot from a distance.
All parameters you asked for should be explained in the owner's manual, and possibly in the help format on the machine.

I think you should be looking at start current and time.
But I lose all hope when you say you're welding AC.

 

[Muhammad Jami Raza]

Oh God ı am ın so much stress due to thıs fronıus, ı thınk there ıs not any kınd of ac or dc labled we just have to select wıre from menu and ıts dıameter and machıne start by ıts self and do pulsed spray transfer. AC ı saıd by mıstake because ı do TIG weld wıth mıller dynasty on AC pulsed.

 

All of the above responses

Call in Fronius tech support. End of story.

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

 

[IFRs]

Confirm reverse polarity?
The workspace distance is very important. Exactly how far is it from the tip where the wire comes out to the metal you are welding?

 

[weldstan]

Second ironic metallurgist. Get Fronius tech out asap.

 

[gtaw]

I am not an advocate for using pulsing when welding aluminum. Generally, you want all the heat you can get. Pulsing minimizes the heat.

The column strength of aluminum is poor, so they do not "push" through the conduit very good. It is feasible if the conduit is short and a teflon liner is used. As mentioned by several people, a push-pull gun or a spool gun is the best option.

Don't over tighten the drive rolls. Use U-grooves, not V-rolls typically used with flux cored electrode. Too much tension will deform the electrode so that if will hang up in the contact tip.

The contact tip must be changed anytime you experience burn-back.

Make sure you are in spray transfer mode to generate sufficient heat to obtain proper fusion.

Cut the filler metal with a pair of sharp wire cutters at a 45 degree angle before initiating the arc each time.

Wire brush the base metal with a clean stainless steel bristled brush immediately before initiating the arc. The aluminum oxide has a melting point about three times higher than the aluminum base metal. The groove face should be filed using a vixen file to remove oxides and to eliminate the asperities that oxidize easily.

Make sure you are in the spray transfer mode. Argon shielding gas is fine unless you are welding thick base metal (15 mm or thicker), in which case helium or a helium-argon mix may be preferred.

They don't call aluminum "almost-a-metal" for nothing.

Best regards - Al

 

[IFRs]

My company just finished 66,100 feet of aluminum downhand groove weld in the field using push-pull pulse-on-pulse 100% Argon 0.045" 4043 spools with 25 feet between the wire feeder and the gun. Miller Alumafeed units running 220 3-phase from 20 KVA diesel gensets to custom distribution boxes. We only cleaned superficially and vac-box tested 100% with very few repairs required. Not structural or critical welds, just a seal pass. It ain't rocket science !!!

 

They don't call aluminum "almost-a-metal" for nothing.

I hadn't heard that one, but independent of that I've been saying "aluminum is not a real metal" for a long time. (And plastic is not a real material.)

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