Miller Tig

[larry53]

Does anyone on this site own or used a miller syn 180 Tig?

[Unabiker]

I used one quite a bit at a former job. It was a pretty nice machine.
The only problems we had with it were related to dust that was constantly around the machine.

[larry53]

How did you prepare the electrod to weld aluminum?

[DCparts]

depends on the thickness and type of weld and gas used.

For aluminum 1/8" material and buttwelded, typically use a pure tungsten, AWS Class EWP (green band). Form a balled-end before welding.

check out

http://www.millerwelds.com/education...calculator.php

[larry53]

Did you ever have a problem with the arc wandering? My welder's arc is wandering then seems to staple then wanders again. I have adjusted the post flow,but it still does it. I am wandering if the electrode is the problem,I bought the last one's from McMaster Carr,or something is not right with the welder. Do you have any suggestions on this problem. Larry

[Kool Parts]

larry53,
I think I know what you are talking about. For alum you need a round ball on the end. The easiest way to do that is flip the welder over to DC reverse polarity, then start a arc on a clean piece of steel (yes steel). Hold the tungsten above the steel about 1/4 - 1/2. Careful it doesn't take much power and you will probably blow the end off a few times to get the hang of it. But it will produce a perfectly round end for AC alum tig welding.
Gary

[larry53]

Thanks for the information. Did you ever have a problem making sure the switch was in the AC position? It does not look like I am getting the full amount. Larry

[mxtras]

The switch on my Synchrowave 250 is a bit flaky, too but as long as it is vertical, you are in AC which is what you want for Aluminum.

The wandering arc can also come from a contaminated tungsten. Make sure you play be the rules for post-flow time and keep the tungsten clean.

Scott

[Unabiker]

Your problem could be a couple of things.
You could be picking up some contamination when you ball the electrode over steel. I've got a 2"x3"x.25" piece of copper that I use to ball the electrode. Keeps things nice and clean.
You could have a short developing somewhere. We did have troubles with the wiring in the foot pedal from time to time. Also check the wires from the torch for any short. Check in the torch and in the machine. Really, any wire that could get jerked around should be inspected.
Also, check the gas cup for any contamination.
Dirt bad. Clean good.

[Weldtutor]

Larry
Arc wander when using AC, is generally too large a ball on the end of the tungsten electrode. If using a 3/32" electrode, the hemispherically balled (1/2 round) end should not exceed 3/32". Another cause of "wandering" might be an electrode diameter too large for the amperage being used.
WT

[larry53]

It may be a short some where,because I turn the machine to max volts and max penteration and I could not get the electrode to ball up on the end,the arc was wandering ever so often it would stop wandering. I suppose the foot pedal would be the first place to check,but I do not seem to have a problem welding in dc when I am welding stainless. Larry

[DCparts]

Are you using pure tungsten and turning it to DC Positive to ball it up?

Even with a sharp tungsten on AC it will ball up on it's own because it is changing from DC positive to DC negative very quickly, "AC" Alternating Current.