thanks guys, I went back to a 2.4mm electrode ( much better ) and turned up the Hz to 60, my machine ( unimig 315 ac - dc )maxes out at 70 . I really appreciate all of your feed back to. cheers.

i have a job on where I am welding 40x10mm and 60x10 aluminium flat bar together for a balustrade, I am trying to get a really fine weld, so I started using a 1.6mm electrode, it starts off alright but after about 8 seconds the electrode explodes. I am running 230 amps , does anyone know why ? are t...