I really haven't seen anyone outside of the racing industry manually pulse weld aluminum. Every time I tried searching for others pulse welding it was always the machines pulse settings. I finally stumbled across a video that Jody posted a few months back where he was trying out pulsing with the foot pedal.
I just felt like posting some of my welds to show the type of quality that can be achieved if you become skilled with manually pulsing.
I work in the racing industry, and use a Miller Syncrowave 350LX. I run my machine at 300 amps(my personal pref.) while other in my shop run anywhere from 250-280 amps. With my balance around 80% and maxed out in certain situations to have better control of the arc.
You'll find several discussions on manual pulsing here. One of the finest aluminum welders uses simple on/off pulsing to do stunning work on anodized aluminum.
I've only ever used machine pulsing on very thin material. I often use manual pulsing on aluminum, particulary pipe.
I suppose videos are hard to find, though.
That's some fine work on the oil pan and rocker covers!
Tungsten Wolf,
Those welds look awesome! I love the consistency you have. As far as manually pulsing I do it some but not as good as a machine for sure. I guess I don't have the rhythm down, I will have to practice more. Most of the parts I have welded are not long runs like you have. The most regular item I have is 1/2" rod welded into a "T", not much room for pulsing but it does require a lot of control. Keep up the great work.
As far as consumables, we use i-Head Roto Head torch bodies, 3/32" 1.5% Lanthanated Tungsten, WeldCraft collets/collet bodies, #5 cup, short back caps.
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