why does my arc get funky when filler rod gets near

Im trying to do outside corner welds on .063 or so aluminum. I suck at it. Im not building anything. just trying to stick 2 pieces of aluminum together in a respectable manner.
IF I can get a puddle without melting the edges, as soon as I approach with the filler, the arc starts wandering, and sounds like popcorn. And the filler drips onto the aluminum. I havent dipped the tungsten or touched it with the filler. Im reasonably certain i've prepped the tungsten properly,(longitudinal grinding on a dedicated wheel etc..) and everything is cleaned with a dedicated brush and acetone. im using 1/16 blue or purple tungsten ,powerpro 164 welder, various gas flows from 7-15 lpm of 100% argon,#8 cup, various amp settings from 35 -100. usually around 60.
Did I leave anything out?
Thanks, John

Gee,

With thinner stuff like that, I'll guess that your arc is too long, and it smokes your filler before it gets to the puddle, even with mild amperage.

Thanks, will too long of an arc make it sound like popcorn popping?

If you haven't dipped the tungsten, you probably aren't close enough. ;) A good rule of thumb is to hold an arc length no more than 1 tungsten diameter.
1/16" (1.6mm) material is a little tricky. You might want to start with double that thickness then work down once you get the hang of it. Also some kind of chill bar or other heatsink can go a long way to keeping things under control. Another good practice is to just do some edge buildup welds on thin material before progressing to joints. It helps to use filler smaller than your material thickness. 1/16" filler is great for welding 1/8" plate, but for 1/16" plate, it can be a little much. You might want to try some .045" or .035" to keep from adding too much with each dab.

Yeah,

Touching filler directly on the tungsten, rather than dipping the tungsten in the puddle, can also give you "popcorn". Ha, ha, ha...

The tungsten must be re-ground each time, to have any real chance of a good result going forward.

If you're not seeing the arc and puddle very well, I suggest that you get a good, adjustable welding lid.

Quote:

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Originally Posted by JohnT

Thanks, will too long of an arc make it sound like popcorn popping?

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thanks guys, ill keep plugging away at it