TIG Aluminum Setup and Settings

TIG Aluminum Setup and Settings is a video I made to answer the questions I keep getting. Hopefully this sheds some insight into getting your TIG dialed in!
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[@5thStreetFab]

Hey Guys Ive been getting a lot of questions about set up for aluminum so hopefully this helps!

[@FrequencyOfThought]

Hey brother Im about to start a channel as well. Glad to see you starting out trying to help people.

[@5thStreetFab]

@@FrequencyOfThought right on dude and thanks bud

[@KillaCowboy]

What's your welding machine?

[@scotchlobster6599]

Thank you very much for these videos.

[@soldieroftoughlove7635]

9:28 what needs to go up?

[@Skeetmgeett]

It's nice learning aluminum from someone who clearly knows AC. Good to see you back. I wish a certain company (cough HTP) would get you a fancy new tig welder for more aluminum videos, total no brainer htp.

[@5thStreetFab]

Thanks dude! That would be awesome! Hopefully they see it our way!

[@fredrico373]

This is The Video off all KZbin certified mechanical, thank you very much!! I've been trying to find this information for a long time.

[@1navynasa2]

Brother, thank you for this tutorial and explanation, what a difference! I'm welding aluminum for a long time and most of the time got good results, never thought about playing with the balance... good lesson :) Thank you!

[@elijahtaylor8351]

This video definitely helped me. I haven't welded aluminum with my everlast welder yet.

[@5thStreetFab]

Glad to hear it bud

[@nicholaijerome7583]

Love the Lanthanated T! I don't weld much aluminum, but I have a project this week, thanks for the fresher!

[@senecalfab1487]

Awesome video explaining what I was seeing today my first time TIG welding and how to remedy it! Thank you!

[@5thStreetFab]

That's awesome glad to hear it! Thanks for watching

[@JohnnyFaber]

Thank you SO much for this video! The way you illustrate and explain things really really helped me get it! I was getting frustrated and after some of your vids I was stacking dimes!!!! So stoked about it! THANK YOU!!!!!

[@taylorsmith9127]

Pretty much on point man only tip I'd give is the crater cracks at the ends of ur weld slowly let off at then of a weld and swirl the torch that will get rid of those sometimes an extra dab is needed but those crater cracks are stress points

[@jrautofabwerksllc7556]

I really appreciate the settings and tips and tricks for kids ❤️ help me weld aluminum

[@JP-yt3nk]

Fantastic tip on cleaning. Never thought of turning up the balance that high, was going by the cleaning zone around the bead and trying to keep that tight. That may be my issue, not just heat control.

[@5thStreetFab]

I had to turn it up so high because my machine was crapping out! Most machines would be fine around 65%-75%. After that you moght aant to try uping your gas flow!

[@FrustratedBaboon]

Nice work 5th. I went away few years from welding but thinking to get back to it. I found a 25lbs aluminum CO2 tank and may cut it up into a go kart fuel tank for practice.

[@Urchfab]

Good to see you back on the vids mate. great video as always.

[@5thStreetFab]

Thanks Matt! I'm trying to find time!

[@dreammakergarage1133]

I learned so much from this video. Thank you so much for sharing.

[@farvatron]

Thanks man this video is very helpful! I just bought my first welder, an ACDC TIG of course because why not!

[@bigbothoee8617]

How you getting on with your welder ? Did you manage to setup ok ? I'm just waiting for my welder to turn up

[@farvatron]

@@bigbothoee8617 it's easy as, you'll be fine just get some scrap and have a go :)

[@bigbothoee8617]

@@farvatron swweeeeeet thanks

[@LifeInHyrule]

Great video well done. Have you tried playing with gas flow settings as well? My experience has been upping the gas flow has a similar effect of increasing the cleaning percentage. Down side is more gas used, but the up side is the tungsten can maintain a sharper point keeping the arc more direct.

[@FrequencyOfThought]

For the longest time I thought balling it was a bad thing and would regrind my tungsten but I found that the balling actually promotes the welding arc zone to be more predictable and the heat gets put into the material where you expect it versus a sharp tip that seems to pierce holes in the material. Hot and heavy versus controlled and medium pace. Considering aluminums melting point is lower than almost all other materials balling it makes good and complete sense.

[@5thStreetFab]

Ya everyone has their own preferences. it's probably how you learn more than anything.

[@zeebee6702]

Very helpful video!!! Thanks for taking the time to explain some of your tips. I was struggling with some basics and you had some very good reminders.

[@davidswanson4437]

Do the Ball, Be the Ball, but one doesn't need to. Cleanliness is next of godliness. A clean aluminum has a thin layer of aluminum oxide that needs to be removed with the positive side of the AC cycle, thus saving the tip. For the most part, even with 1" thick aluminum on a Miller Aerowave (350 amps, Tri-Mix 1/8" electrode, some balling, but not complete ball). Think about it. The positive side of the AC cycle removes the aluminum oxide instead of melting it (3,762°F melting temp). The electrode negative cycle melts the aluminum at 1,220°F. Helium gas ($$) and high amps are used on pure DCEN for aluminum when the cleaning ("cathodic etching") can not be tolerated. Remember Heliarc? If a sharp tip punches holes, turn down the amps - practice welding aluminum soda cans together (remember most machines HF start is with higher amps). ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/20040139717.pdf "Because the electrons extract heat from the cathode {work piece} and deliver heat to the anode {electrode}, the welding process is considered to be more efficient when operated in “straight polarity,” when the torch electrode is negative, the workpiece positive, and electrons flow to the workpiece. Unless there’s a reason not to, welding torches are operated in the straight polarity mode. But there is a reason to weld in “reverse polarity,” where the electrons flow away from the workpiece: the cathodic cleaning effect. A high speed movie of the vicinity of a GTA weld pool in the reverse polarity mode will reveal a display of sparkling points of light, miniature explosions continually occurring all over the surface. This is thought to be caused by electrostatic breakdown of a thin surface oxide layer. The positive ions in the arc accumulate on the surface of the oxide layer and induce a balancing negative charge. If the oxide layer is thin, it doesn’t take a lot of charge to produce an electric field (volts per distance) big enough to cause the oxide layer to break down in a mini-explosion. Cleaned surface is distinct and visible around the crown of a weld made in reverse polarity. But to get the cleaning necessary to weld aluminum alloys one takes a hit in power available for welding, and the effective capability of the machine is reduced." Hope this helps, David

[@jonwatkins254]

Fabulous Video. Thank you for sharing the comprehensive and densely packed knowledge.

[@5thStreetFab]

No problem bud! I really appreciate your comment.

[@mattfuchs7626]

Great instructional video and process steps, very helpful!

[@johnversluis3084]

Thank you !! so much this really helps setting up and a little more understanding how to setup AHP Happy New year !!

[@5thStreetFab]

No problem bud and thanks for watching hopefully it'll help you out

[@parikapustina1398]

What did you change to get a better weld each time? You didn't describe

[@bigj7807]

Nice ! I have the same welder, good explanation of how frequency and balance actually affect the weld and what too look for when adjusting. Do you have a video on doing stainless ?

[@oldscar6169]

AHP welder good instructional thank you

[@paulmattox]

Never really done aluminium. Would love to do more at work

[@maxlindgren5986]

Really nice video, i will go to my garage and try mixing with the settings and hopefully i will get much cleaner and better welds! :D This really helped me a lot!

[@5thStreetFab]

Good luck bud hope it helps

[@alec-s]

What changes very much between a pass and the other in those you made, is the sheet has heated up and you can get a faster and more precise fusion.... The real deal is the heat, sometime you should spend time in heating without sticking the rod in, just to increase the heat before you weld. For the heavier parts, ( 1,5 inches thick) sometime you need to fire preheat the part before start welding....

[@5thStreetFab]

I was showing the cleaning action nothing to do with the heat. I preheat most of my parts at work we weld anywhere from .063" to 2" thick. I only like preheat on parts 3/16" and over

[@davidcizek4024]

Hi Max …i Love your Videos i can learn alot of them …because i just started tig Welding and i Love it😀 Most of all aluminum…keep up sharing your knowledge it is a BIG help for beginners like me👍 Happy new year from Vienna Austria👍 David

[@5thStreetFab]

Thank you bud I appreciate it! I'll try to keep putting out videos! And happy New year to you too!

[@steveh9106]

Hi there, great video again for beginners, well explained and not to technical, with advice on Hardwear too, thanks for your time 😀

[@5thStreetFab]

No problem bud and thanks for watching!

[@pitu66bat59]

Legend in vídeo setting usage

[@bigbothoee8617]

Perfect vid just what I wanted straight to point

[@markbroad119]

Nice, I've got that exact welder. Love that lil welder.

[@PYWong-jq4pg]

Awesome thanks! I always learn something useful on your channel. Gonna try those settings.

[@5thStreetFab]

Thanks bud! I'm glad I can help. Good luck!

[@shaun2049]

Thanks dude l find the settings harder than to weld just started welding ally’s hard

[@adamedgar5765]

interesting comment about gas...other youtubers who are fabricators say that aluminium is not reactive to air environment. The gas is to protect the tungesten...not the aluminium. I innadvertantly ran out of gas the other day whilst TIG wedling some aluminium tubing and it didnt make any difference. The main way i knew it was out of gas was because of the sound difference but i kept on welding for quite a while to see what would happen...the weld was fine.

[@5thStreetFab]

Nope thats not correct. The gas does protect your tungsten but it also protects the molten aluminum. you dont need much coverage because as soon as the puddle solidifies the oxide layer that forms shields it from regular atmosphere. But until it solidifies you need argon coverage or you can get porosity and a dirty weld

[@adamedgar5765]

@@5thStreetFab i am wondering if you could do a video tig welding aluminium to show this with aluminium tubing and aluminium plate? I know with Mig welding i have never had any success without gas, i also thought TIG would be the same...so i was suprised to hear it can be done without.

[@t54760]

I have that exact model AHP. Can you go into a little more detail on the problems you are having with it? I'm still relatively new to the aluminum side of welding and this is my first Tig machine. I guess what I'm trying to help determine is whether the issues are me or the machine. Another great video and Happy 2019 !

[@5thStreetFab]

Ya im not sure exactly what's wrong. I think it has something to do with the alternating current being messed up almost like you need way more ac balance to correct it. But it makes it look like porosity is constantly burning out. The weld looks very grainy. And happy New year!

[@t54760]

Initially, my aluminum welding was what I would have expected from a beginner and thought the learning process was going well. Then after a few months, I was welding some very thin wall aluminum square tubing and was having difficulty with arc starts. When I did get it going the arc would wander all over the place. This caused burn through. I Googled it and it turns out there is a set of points inside of our machines that wear and lose the proper gap with time. I followed the instructions, cleaned the points and reset the gap which was off quite a bit. This made it better but I still don't think I have the same performance as when I first got it. I would love to find a fix for this. The DC side still works great.

[@5thStreetFab]

@@t54760 yep I did the same thing but still not as nice as I like!

[@whoisjohngalt11]

I don't understand the point of balling the tip. Why not just round it off with the grinder instead of grinding to a point and then balling it off? By the way, I really appreciate that you did such a good job explaining the settings on this particular welder since I just picked one up. I'm going to run some beads with your settings tomorrow. I'm just getting started and I don't even know where to begin with settings.

[@5thStreetFab]

i like sharpening it first because its more consistent everytime. Thanks!

[@juanmangerita]

I have the same AHP welder and been having a hard time dialing it in... Do you use the torch that came with the welder??

[@HandWiredAmps]

10:14 Vented back cap! I need one of those. 👍

[@5thStreetFab]

Haha easy to make too!

[@ZILAwelds]

You need an htp 221 .... everything is “different” with a different machine .... the htp 221 LOVES 2% ceriated and has hard times arc starting with 2% lanthenated .... and the cleaning and penetration is “backwards” so 35% would be 65% ..... the inverter and the arc dynamic is so good that you easily weld at 70-75% on super clean material i even welded on 90%! And you have independent En+ and En- adjustments Water cooled guns will help you a lot with running high penetration numbers and high amperages on tungstens that “normally” would crack ....

[@split150]

I have a 221, and have noticed the same thing certain times when using Lanthanated tungsten. Always thought it was just me, or a bad ground or something. Never thought about it being the tungsten type. Thanks.

[@5thStreetFab]

dude that sounds awesome! I know this machine is definitely on its way out as far as the ac balance is considered. thats crazy. Ive always wanted to mess with the independent en adjustments. Sounds so cool!

[@ZILAwelds]

split150 on the 221 lanthenated is not a “good” choice. 2% lan has arc starting issues and 1.5% lan has a weird erosion pattern .... The funny thing is that in some European forum stel 221acdc customers ( which is effectively the identical machine ) have said that some equipment dealer or sales rep told them not to run lanthanated but encouraged them to run 2% ceriated and only if they cant get that run 2% thoriated ..... no lanthanated .... i found that pretty interesting .... And then if you put helium mixtures in the mix ..... arc starting suffers majorly in addition and arc stability suffers a little bit too.

[@5thStreetFab]

@@ZILAwelds wierd I would figure tungstens would act similar from machine to machine. Very interesting

[@ZILAwelds]

5th Street Fab all machines are a little bit different .... they all have their own idiosyncrasies ..... what works for one machine does not have to work for another machine ....

[@WelcomeToTheMadness]

Learnt a little something...

[@theragingredneckhaulsoff6760]

Awesome video!

[@user9005]

I first thought zirconiated tungsten was the way to go but everyone is using lanthiated tungstens

[@williamhayes136]

Sorry bro I'll keep my opinion to myself you do a good job

[@williamhayes136]

We all got our own opinion on this this smaller works for me and I would use pure Tung

[@johnmacmillan627]

Clearly shown. Thx

[@nameofdane]

TONS of good tips! Thankyasir, gonna try and put some of these to use today.

[@marcusmorgan1419]

Nice video, thanks for sharing with us newbs something useful.

[@5thStreetFab]

Anytime bud

[@v8consumption]

On my ahp I think the balance is backwards to most machines I generally keep it at 30% which gives less ball more sharp arc

[@5thStreetFab]

Mines the same way but the AC was crapping out on me and I had to run super high balance to counteract it

[@reddyreddy2618]

0:05 if the belt had grabbed a hold of that tungsten you could be in for an injury, don't angle in to the direction of a sanding belt people

[@Slouworker]

You don't even need to ball your tungsten with modern machines anymore

[@danysperez-carrillo6630]

Thanks for posting

[@trailerpark187]

I always ran my balance on my syncowave at 10. But then I got a dynasty. Do you have a dynasty setting video? There's another guy on youtube but he charges a subscription fee to see his settings

[@luisfernandotorres6980]

Hi i take at picture of my tig and i like u teach ne how can setup for weld aluminum 1/8 sheet

[@thomasmonsenego-mo8140]

What setup are you modifying during your different tries at more or less 10 minutes. The balance ?

[@adamkwiatkowski4107]

I like blue tungsten. Do you have amazon link to tungsten ? Thx

[@jordanhenningsen7938]

Another great easy to follow video! Please keep them coming. I How do you cut your 2% lanthanated tungsten without cracking or splintering? I’m yet to find a easy quick way. I miss the quick snap of the thoriated tungsten.

[@5thStreetFab]

I usually just hold it 45° at the edge of the belt sander until it cuts through most of the guys at work still snap the Tungsten but it splinters too much for me

[@wonghunglo1]

i use small cutoff wheel on a dremel. snapping makes it splinter alot of times

[@weldingjunkie]

Band Saw works great i use it on my swag table and cut them to any length,

[@ion_canadianu]

I have a lincoln 200 tig. It’s good for aluminium welding ?

[@tommylud4324]

What do you feel the balance would be if you cleaned with acetone and then a brush?

[@5thStreetFab]

This AHP was on its last leg on my htp I'm around 75% dcen each machine is a little different that's why I like to do this test

[@williamhayes136]

Switch to a smaller cup so you get a smaller heat line

[@rtt931979]

Hi! I have a Unimig 170A viper machine. My AC balànce adustment in the machine is only between 1-5 im confused and dont know what proper adjustment to select on it. By the way im just a beginner and im using Zirconated (white).

[@boostedpower5417]

Thanks dood I needed this!

[@robertbasile4191]

Hey, my machine (Hobart ez-tig 165) doesn't have frequency or balance adjustments. The cleaning line is basically right up against my bead. Having trouble making good beads. Any idea what I can do? (16 gauge aluminum)

[@danssv8]

Thanks , so you using a pedal right??

[@turbotrana]

Good info there. How about setup for thick aluminium cast cylinder heads.I struggle on them (only played around on them) and have seen a pro do it easy. I need to play with a few settings.

[@5thStreetFab]

All the thick castings I've done have been on a large transformer so I don't have any settings other than 60 Hz and a lot of cleaning. 4943 filler is awesome for it too

[@kdk200]

How hot were you when doing the beads? If I did exact same thing it would be too hot to touch after 3 or 4 beads. I weld with 120amps. Is that too low and I'm slow?

[@gaminacthemaniac6444]

Would Thoriated tungstens work alright?

[@hipairbrush1053]

great video

[@jakeowens1770]

Looks good sounds like beginner

[@chrisbec3313]

Very informative! Thanks

[@octomulianto215]

How setting machine for thin aluminium, I have problem about it

[@CarReporter12]

Hi. Great video. I am planning in buying a tig welding machine. My main use are building exhausts for my own cars so basically SS304/316 and titanium. But I might have to weld aluminum say for making brackets etc. but that will be very very rare, since I have shortlisted a AC/DC machine rated at 250amps. Will it be sufficient for alumium?

[@DJCallitquits]

Learned a lot in this video!! Thanks!!

[@5thStreetFab]

Awesome and no problem bud!

[@mytube3687]

Is it possible to weld mild steel or stainless steel or Aluminium using Tig welding machine without gas? I mean is there special filling material which doesn’t need gas?(like MiG welder there’s gasless flux core wire you can use without gas for mild steel).

[@Slouworker]

No. Just stick weld it if you don't have gas.

[@rattedbug5003]

tHanks for the tips very helpful

[@ayazkhan-bm5uh]

Nice video and information. Thank you one more information. Welding definition.

[@uniquemotivational1152]

How much amps use for 1mm and 2 mm ss sheet

[@traininggrounds9450]

Just accept it with AC, it's balled up or it ain't welding. E3 and other harder tungstens don't ball up consistently to be good production rods for AC. Blue is better than purple and pink is better than blue when it comes to arc stability but I believe white to be the best tungsten for AC every time. Just get E3 for DCEN only and white for AC only and you'll make the best welds in both worlds.

[@mikerrr82]

Hei. What tungsten for thin sheet alu and thick alu?

[@johnmacmillan627]

Thx

[@cubegears]

what size torch is that? 17?

[@Brandon_Audi]

What series torch are you using in this video?

[@weldnfab7136]

How did you fit that cup on that torch ? Any adapter ?

[@starmanxv2331]

Well job . I have learn from you .💪

[@geraldturkeyhunter]

Pre heat your metal you kept welding on same piece over over til you hit the sweet spot pre heat it do same thing once

[@chadandrews98]

Thanks for good information

[@andrewsigler2467]

Ive always been told to use pure tungsten on aluminum. Is lanthenated better?

[@5thStreetFab]

pure is what they used to run years ago on really old machines but now days there are way better choices like lanthanated

[@geraldturkeyhunter]

Ps clean clean clean oh and clean it prep work heat before if it's old funky stuff

[@pararescue88]

Perfect video

[@fastcash9799]

I have a Lincoln inverter machine do you still need to ball up the tunsten for aluminum?

[@5thStreetFab]

personal preference I usually put a small ball on my tungsten seems to help the cleaning action work better

[@NSXTACY420]

What balance percentage did you end up on at that last nicest looking shiny bead? 40%?

[@5thStreetFab]

It was actually something like 55% but I wouldn't trust it. This machine has been giving me big problems on AC

[@tysonhimself]

Good tips thanks

[@georgesmirnoff9751]

Thanks brother! Man, I watch all the videos all the time but my welding still sucks, what should I do? ; )

[@5thStreetFab]

Haha just keep practicing bud

[@outkast187]

Quit.

[@tinybuilds2132]

Hi What is the base metal that you are using

[@5thStreetFab]

5052 aluminum

[@tinybuilds2132]

Thank you 🙏

[@gyulakiss420]

Helo! The polariti change no change cables?

[@RJB510]

Leave cables as DCEN on Tig for alloy as well as most other tig welding types. Remember that alternating current effectively swaps your polarity anyway and the settings on your machine will most likely require your electrode to be connected to the machines negative terminal. You want to swap cables when using it as a straight dc stick welder.

[@TonywithaT]

You’re smart. Cheers!

[@ion_canadianu]

👍 merci

[@jimmiemires2644]

What is "annoying" about a tight bead?

[@5thStreetFab]

I meant the noise of a high frequency around 200hz

[@drumtwo4seven]

No 3 👍 Sweet video