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99% of the time, we run 1/8” Tungsten on ferrous and non-ferrous materials ranging in thickness from 24ga (.025”) to 1/4”+. BLUE Tungsten for all Ally work, and RED Tungsten for all other materials. Inverter machines. The key is end preparation, tip profiling, and operator proficiency. We also micro-ball the tip for Ally work. Yes, even when using inverter power sources.

Watch Aaron @ 6061.com master 1/8” Tunsgten on thin/thin, medium, and thick Aluminum and Stainless.

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Purpose, then passion. Practitionership. Obsession and hard work. That's the discipline.
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Here's some aluminum foil I welded at 10 amps DC- with a 3/32" tungsten :D

No light shined through when I checked, but it did have a tiny pinhole when I water tested it... :oops:

At 10 amps, when I first lit the tungsten on scrap the arc was just a buzzing large electrical field all over.
After the arc stabilized it didn't do that again and continued lighting up normally.
I had sharpened it on the belt sander, no polish - that's likely why.
Foil closeup
Foil closeup
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Machine
Machine
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image.jpeg
image.jpeg (46.55 KiB) Viewed 1024 times
Dave J.

Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~

Syncro 350
Invertec v250-s
Thermal Arc 161 and 300
MM210
Dialarc
Tried being normal once, didn't take....I think it was a Tuesday.
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@ MinnesotaDave - fusion welding aluminum foil is about about easy as it comes. Amps aren’t key, fixturing/fitup is crucial. Now, if you fused the surfaces via “open root” you’re a king.

Ron C shows his craft on 1thou Ally,

https://youtu.be/0p9s3DxMZ0A
Purpose, then passion. Practitionership. Obsession and hard work. That's the discipline.
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Arclight Ironworks wrote:@ MinnesotaDave - fusion welding aluminum foil is about about easy as it comes. Amps aren’t key, fixturing/fitup is crucial. Now, if you fused the surfaces via “open root” you’re a king.

Ron C shows his craft on 1thou Ally,

https://youtu.be/0p9s3DxMZ0A
Quite right, it's very easy :D pics are just a bonus - lol

Mostly I was just noting what happened with the 10 amps on my unpolished 3/32" tungsten.

I used two strips of stainless and sandwiched the foil with a little sticking out.
I went much slower than Ron C. because I wanted to watch the fusion take place.
I found it interesting :)
Dave J.

Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~

Syncro 350
Invertec v250-s
Thermal Arc 161 and 300
MM210
Dialarc
Tried being normal once, didn't take....I think it was a Tuesday.
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6061 had some recent videos about tungsten size.
Can't say I've seen his videos brought up on here though.

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79jasper wrote:6061 had some recent videos about tungsten size.
Can't say I've seen his videos brought up on here though.

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Well, he has posted many pics of his work and occasionally a video. He does have YT videos and a pay site
Richard
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I couldn't weld as good as 6061 "Aaron" in my dreams, guy has skills! ;)
Pete



Esab SVI 300, Mig 4HD wire feeder, 30A spool gun, Miller Passport, Dynasty 300 DX, Coolmate 4, Spectrum 2050, C&K Cold Wire feeder WF-3, Black Gold Tungsten Sharperner, Prime Weld 225
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