Welding Tips and Tricks

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.

Welcome, Wolf,

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!

Steve S

A couple more.

wow, excellent work my friend.
I'm guessing your using a 1/8 pure tungsten?
What torch consumables are you using? sizes brands etc.

~John
ps. welcome to the forum.

Looking good. I've tried manually pulsing at work to mimic the orbital welder, but it's just not the same as automatic pulsing.

Im digging those covers as well. They really look splendid. Very uniform.

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.

Verry nice good job all is good Tungsten Wolf.

Very nice work ..

I appreciate your responses.

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.