I typically TIG weld 1/16" steel parts and will be working on aluminum of similar thickness in the near future. My welds tend to be bigger than they need to be (~ 1/8" wide or so) and I'd like to know how to get the beads smaller. I typically try to use a .040 electrode and a similar size filler wire but the welds always end up bigger. I'm an amateur at this and can do a decent job. I have just upgraded to a Miller 200 Dynasty DX, but so far that hasn't made any difference. I don't practice like I should, but since I have never been able to actually create the smaller weld beads, I don't know what to practice..... Torch angle is about right, electrode tips have a longer point rather than shorter and are ground correctly, current settings are ballpark correct (~60 Amps), fit-up is usually good as I don't want to melt the parts before I get a bead going. I do have good success on 1/8" thick steel. I don't recall seeing any videos on smaller beads and a search on this forum didn't turn anything obvious either.
Any helpful suggestions? Thanks in advance.
-Jim
Welding on AC with your Dynasty, you can change the frequency to 150Hz or higher and get a more focused arc. Set your balance to about 72, and switch back to a 3/32 tungsten. A 7 or 8 cup with a gas lens will offer better gas coverage and help protect the adjacent areas.
As for taper angle of your tungsten, a narrow tip creates a wider arc higher up the tungsten. So you’re crossing yourself by trying to keep a narrow arc with a needle taper.
As for taper angle of your tungsten, a narrow tip creates a wider arc higher up the tungsten. So you’re crossing yourself by trying to keep a narrow arc with a needle taper.
Dead right. But the same principles apply. The nice thing about AC with his Dynasty, is the adjustable freq. It can make a huge difference in weld size coupled with controlling the balance. Of course, "tuning" can't overcome "technique" issues.LtBadd wrote:Even so, the aluminum weld will be larger then a stainless or steel weld would be given the same material thickness and joint configuration.
