Thanks again for all the help and replies. Our lateset attempt was to take the coupons from the machine shop, wipe them in acetone inside and out. Then we put them in an oven @ 200 degrees for at least 24 hours. We took the coupons out, used a new small stainless hand brush with one direction stroke...

Thanks Noddybrian I will try to answer what we have done under each suggestion Amps seem low based on my welders dials but yours may vary - seems like it would take too long to establish a puddle & cause heat soak. We are using a foot pedal are running about 115-120 amps with a 200amp upper lim...

We started using the Weldo after our first set of tests failed xray for porosity thinking we didn't clean the pipe thoroughly . The coupons we used before Weldo were cut on a lathe with cutting oil, flapper wheel cleaned and then acetoned. I don't think I could get anymore porosity in the pipe if I ...

Thanks for the replies.
I will give it a try today with 60 sec Weldo dip on the pipe and 60 seconds on the wire.
The rags are made by Contec and called CleanTube (TM) it is a Lacoste Knit.

Yes, new pipe that was machined dry without cutting oils. Pipes are 6 1/2" long with a J bevel. We take a lint free cloth, soak it and the pipe in acetone, push the rag through the pipe, and wipe down the outside. Then it is submerged in Weldo (hydrofloric acid) for two minutes. Next the pipe i...

Moto, I can't offer any advise on the pulse/no pulse, but on the coping fit ups I use Pipemaster tools. Perfect every time.

http://www.trick-tools.com/Pipemaster_C ... Gauges_150

6061-T6 pipe 1.25x.125
Filler rod is Alcotec R5356 3/32

Yes sir, We are keeping the tungsten to about 1/4 stick out, gas flow is now at 15 cfh and we switched to 100% ultra pure argon. We cut the wire off at least 1/2" everytime. Wire has been wiped in weldo...welded with, and then we tried wiping with just acetone. Still getting porosity in the sta...

Thanks Zank, I will give that a try.
I have started grinding every pass to see where the porosity is getting in at. Looks like every start I have there will be guaranteed porosity and then just random places through the weld.
I will try to upload a cross cut pic of the pipe later on.

Thanks for the advise and quick replies. I talked with our welding supervisor about changing to a different wire brand as recommended here. He said that he has already talked to the "chief" about a better brand of wire but he is dead set on using Alcotec 5356. :shock: Thanks again for all ...

Thanks Big Gear. We had upped the cfm while on the argon/helium mix. Will give it a go at 15-18 and see how that goes. Thanks for the input!

Hello All We have been fighting porosity in our test samples and would like for a fresh set of eyes to look at this. Pipe will be x-rayed. We have tried 100% argon and 25% argon 75% Helium flowing at 30cfm Welding 6061-T6 pipe 1.25x.125 with a J bevel tacked in two places. Pipe has been wiped down w...