Problems TIG'ing thin-walled aluminum tube

[will701]

I'm trying to weld pieces of 6061 tube together which are .032" thick, 2.5" wide.

I just got a Miller Dynasty 200DX and I am still learning how to use it. I'm using a/c, 150amps, but I'm not sure of the other settings I should have setup on the machine to make a good weld. It just wants to burn through the pipe wall no matter how delicate I am with the foot control, it goes from not melting to melting the wall and cutting back from the edge, how can I weld this joint effectively?

If anyone knows about my welder and could help me I'd really appreciate it, I'm trying to get this project completed.

~Will

what should argon be flowing at?
what amperage should I run?
I'm using 3/32 filler wire
what about all those frequency and intial slope settings?
I'm confused!

 

[Rich2001]

Try these -

Welding Current 60 to 80 amp range
Travel speed - 12 ipm (5.1 mm/sec)
Wire Dia. 1/16" (1.6 mm)
Argon Flow 14.5 cfm (7lpm)

 

[ornerynorsk]

Filler too large. Even 60 to 80 amps is too much curent. TIG takes practice!

 

[stanweld]

Manual open root, TIG welding 6061 that thin (.032&quotis a real art!
Recommended current: 45-55 Amps with Argon shield
Argon back purge at 8-12 CFH
0-1/32" root opening with square groove bevel
.035" ER5356 filler
Preclean (power brush)with clean stainless steel brushes (you may wish to use a (Drimel drive system)
1/8" diameter EWP or EWZr electrode.
Travel Speed: 10"/min minumum.

And have a steady hand! Good Luck! As ornerynorsk says PRACTICE!

 

[will701]

I had better luck using 1/16" electrode and 60 amps, but still not great. I will try your suggestions as far as the even lower amperage. I do have to pick up some much thinner filler rod though, I know it's too big.

Much appreciated!

 

[Sparweb]

We never have it turned up above 50 Amps. Stick with it! Ornerynorsk is right.


"Simplicate, and add more lightness" - Bill Stout
Steven Fahey, CET