Best tig welder for thin aluminum?

I weld aluminum everyday on my 250ex, as long as I am welding thick aluminum to thick aluminum or thick aluminum to thin aluminum it leaves beautiful welds. I have never got it to weld thin stuff like .065 as good as I would like.

Does anyone on here weld thin aluminum on a regular basis, if so what kind of machine do you have and can you post some pics of your work?

I would kick the idea around about buying another machine, if it was better on the thin stuff.

Here is a pic of what I weld.

http://i854.photobucket.com/albums/a...st250EX004.jpg

I don;t think it is a problem with machine selection, rather technique or settings.

What problems are you having?
What machine settings?
What filler wire size?
What type of joint?

My 200Dx does a great job on .025 aircraft aluminum, Welding panels up and adding brackets to sheet parts.

Quote:

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Originally Posted by srp

I weld aluminum everyday on my 250ex, as long as I am welding thick aluminum to thick aluminum or thick aluminum to thin aluminum it leaves beautiful welds. I have never got it to weld thin stuff like .065 as good as I would like.

Does anyone on here weld thin aluminum on a regular basis, if so what kind of machine do you have and can you post some pics of your work?

I would kick the idea around about buying another machine, if it was better on the thin stuff.

Here is a pic of what I weld.

http://i854.photobucket.com/albums/a...st250EX004.jpg

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.065 isn't all that thin. Now, .0065...well that should be the machine's limit or there about. From the looks of the larger welds, it looks like you are getting way too much cleaning. I'd start there. What's your balance setting running on average? Frequency? What type tungsten? Diameter? Amps? Like to help if we can.

What exactly is happening when you are trying to weld that thin?

Photos of the problems would help a lot more than photos of what works good.

Quote:

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Originally Posted by cbmkr

My 200Dx does a great job on .025 aircraft aluminum, Welding panels up and adding brackets to sheet parts.

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Wow. that's pretty thin.

I spent most of the day adjusting the welder out for thin aluminum, I always use 5356 because it welds so much better on the 250ex and the Syncrowave 250. And also that is the correct filler for that alloy, on thin stuff I always drop down on tungsten size to .040.

I was thinking kinda like Mark, needing less cleaning action but that was not what it needed. I was welding at 10% to 20% ac balance and having absolutely no luck, the arc was acting more like a cutting action. I had tried the frequency everywhere as well.

After scratching my head for about four hours I bumped up the cleaning action to 30% and had the frequency at 250, the little 250ex then laid down some of the prettiest welds I have ever seen on .065 aluminum, I just kept going in the wrong direction with cleaning action. I still don't understand why it needs cleaning action 1/4 inch wide but that's what it took.

So I think I answered my own question on what is the best tig for thin aluminum. EVERLAST? LOL

Thanks to everyone that replied with help!