[LtBadd]

I'm surprised you think that the ball I have is huge? I thought I should aim for more than that... i wonder what others think maybe others use a larger ball?

You haven't said what machine you're using but it sounds like it's an inverter, if so you don't need to ball the tungsten, it will ball some as you weld, which is okay.

If you were using a transformer machine then you might want to pre-ball the tungsten, you can do this by setting the machine to reverse polarity (DC+) and with a low amperage gently start the arc and watch as the ball forms, it won't take a lot of amps to do this, when you're done be sure to set the machine back to AC.

Do you have a flat plate or flat bar to run practice beads instead of that angle?

[ONDGAS]

I have a kemppi 2300
Do t get me wrong I didn't just jump in to practicing on this corner piece I have done a fair bit of stee and stainless and even alloy but I wouldn't say I'm a pro at anything. I don't have a pic of the other side of that work piece but it's basically identical outside corner and it was a nice weld, considering I was the one welding it!! What I mean is no schmegma!!! I think the torch angle may be my drama cause the first side went along fine because I didn't have anything in my way, now it's turning to crap cause I have the inlet runners on this manifold in my way and it's just stuffing me up. I dunno how I'm going to keep a good angle on this piece I may take some more pics when I get home

[MosquitoMoto]

Agree with what others have said regarding bad torch angle.

Also, no need to ball the electrode if you are using an inverter.

Finally, your welds look cold to me...hope this is some help.



K

[exnailpounder]

Thanks for the advice
From memory I'm at 1.5 sec pre flow
I'm surprised you think that the ball I have is huge? I thought I should aim for more than that... i wonder what others think maybe others use a larger ball?

I did some AL yesterday and the ball ended up about the size of the roller ball in a pen. Pure develops a huge ball but most other blends don't. I used to have a transformer machine and I used pure and it did ok. When I got my inverter and started using 2% lanthanated , it was like an epiphany. Nice little ball that doesn't want to drop off into the weld, very controllable arc, smaller bead profile...etc. You can grind a land onto the end of your tungsten if you want a bigger ball but there is no need for it.

[exnailpounder]

Here is a pic of my tungsten after I just welded a couple filets over in the "penetration on aluminum" thread. The pic makes the ball look bigger but it's very tiny. This was at 140 amps..your ball will be bigger at higher amps. Nice focused arc that doesn't wander. I know I need to turn up my post flow a little but I am a gas miser

20170426_084543.jpg (34.76 KiB) Viewed 871 times

[ONDGAS]

So what is everyone's thoughts on this picture for welding 1/8 thick alloy... this is why I'm a bit confused on what size ball to have

[Poland308]

Don't focus on your balls!

Take some pictures of the resulting welds that go with the tungsten. From looking at you cup and tungsten that looks totally normal. Every stick of tungsten is made up of a mixture of metals. As you use it and regrind it you constantly exposing new surfaces that may not be quite the same metal mixture. So it will ball up differently every time. Unless there's something wrong with the resulting weld don't sweat it.

[cj737]

Also understand that the more acute the angle ground into your tip, the smaller the "ball" will be. The 1/8" tungsten you posted shows a fairly blunt angle, hence a broader ball. The size of the ball doesn't matter as Poland said, but it will ultimately effect the wandering of the arc.

[exnailpounder]

So what is everyone's thoughts on this picture for welding 1/8 thick alloy... this is why I'm a bit confused on what size ball to have

The ball on my tungsten is smaller probably because of my balance setting. 75% is considered optimum for my machine but I run it about 77-78%. Keeps the tungsten sharp longer and the welds are nice and shiny with no sand. Running more into the cleaning side of balance creates a bigger ball and challenges your tungsten more.

[MinnesotaDave]

i get a nice clean puddle happening but as soon as i put my filler in its turns to crap., through the mask it looks like the filler rod is melting "outside" of the puddle and then my arc gets a greenish type of colour to it almost like it does when i touch the electrode into a puddle by mistake, but the weird thing is i can go over to another part of the work piece immedietly and get a nice puddle going again, sometimes the rod will dip ok for a bit but then bam! it turns to crap. I've tried new tungsten and changed to different filler a couple times but it has me beat.

BTW im a beginer and have been doing Aarons course on 6061.com and he recommends balling your tungsten by turning the AC balance way down, thing is, I've been doing this and i can't get a really great ball on the end of my tungsten as seen in the pic,

16cfh
blue electrode
ck gas lens #7 cup

What amps and what material thickness (I may have missed it)

If the filler won't make it to the puddle, the puddle might not be formed enough yet due to low amperage.
If your puddle is ready in 3 seconds or less, you've likely got enough amps and have added them fast enough.

If amps are not a problem, then bad torch angle will do the same thing.
If your filler rod and tungsten are facing each other at approx the same angle, the filler will try to melt before it gets to the puddle.
Heat "bounces" off at the same angle it's put in, keep your filler rod under this bounce.

On outside corners, I shorten my stickout to help with shielding gas issues.

Of course, everything I've written is "in general" so there are always specific cases where I do something else.

My Airco has no adjustment so it's 50/50, my Dialarc I run 60% penetration, 40% cleaning.
I do not pre-ball the tungsten, they ball on their own as I weld.
Sometimes I use thoriated, sometimes pure.

Keep at it - it always gets better