Welding Tips and Tricks

I would grind out the crack almost all the way through. Then weld one pass with filler. This first pass will likely be full of porosity and flakes of junk. But you grind out some of that nastyness and do the same thing over again. After one or two or three times most of the oxidation and contaminates will be gone. Then you have a solid base that will allow you to build on till you fill it out.

...Or, you grind it open, preheat with Propane to purge impurities, then clean with Acetone and Stainless brush. Then weld it up. Same process I've used heaps of times welding Jon boats impregnated with alkaline heavy water and mud. Its not fun, its not easy, but its very doable. I have never used He on these jobs, just straight Ar, though I have something coming up I might just whack it with...

Thanks for insight, glad that I didn`t agree back then to use mig (Lincoln magnum I guess) that boss showed me and weld aluminium. Only thing I knew back then, that for AL welding you need round rollers and special liner. I would make a great hole in that tipper.

Hi guys I'm new to the forum but not new to welding. I have been welding for a couple aerospace companies in Southern California. Anyways yes you can weld aluminum in DCEN with 100 percent helium high purity grade not balloon grade. If you know how to weld it it comes out just as nice as ac or even nicer, especially if it is really thick aluminum like 3/8 or thicker.

Gon-Welding951 wrote:Hi guys I'm new to the forum but not new to welding. I have been welding for a couple aerospace companies in Southern California. Anyways yes you can weld aluminum in DCEN with 100 percent helium high purity grade not balloon grade. If you know how to weld it it comes out just as nice as ac or even nicer, especially if it is really thick aluminum like 3/8 or thicker.

Welcome to the forum, is this process used at your facility? Got any photos you can post?

LtBadd wrote:

Gon-Welding951 wrote:Hi guys I'm new to the forum but not new to welding. I have been welding for a couple aerospace companies in Southern California. Anyways yes you can weld aluminum in DCEN with 100 percent helium high purity grade not balloon grade. If you know how to weld it it comes out just as nice as ac or even nicer, especially if it is really thick aluminum like 3/8 or thicker.

Welcome to the forum, is this process used at your facility? Got any photos you can post?

Yeah! Pictures or it didn't happen....

Haha yeah here are a few jobs I did with DCEN, it's my first time posting pics. so hopefully they show up. And yes where I currently work we use DCEN.

You and the shop you work at rock. You've set the benchmark very high.


Sent using Tapatalk

Now THAT is aluminum welding! One question..what are those?

Pretty darn cool Gon-Welding951

Since the amperage is dramatically less with DCEN on aluminum, mind telling what amps (approximately) those were welded at for reference?

Very nice work

Thank you guys. Usually on 1/4- 3/8 around 205 amps anything thicker like 1/2- 2" 210- 250 amps. My favorite set up is a 3/32 red band tungsten #7 gas lens and 40- 60 cfh on helium.

What is the max thickness of Al you can weld with 160amps DC? (curious `bout this machine Migatronic Rallymig 161i)

Gon-Welding951 wrote:Thank you guys. Usually on 1/4- 3/8 around 205 amps anything thicker like 1/2- 2" 210- 250 amps. My favorite set up is a 3/32 red band tungsten #7 gas lens and 40- 60 cfh on helium.

Thanks for the info - pretty cool process