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Thread: AC weld testing with Everlast 250 EXT

  1. #1
    Join Date
    Oct 2011
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    Default AC weld testing with Everlast 250 EXT

    Below are some notes from some testing on the 250EXT. I have attached a picture of the weld practice. I also ran a few beads with the final settings on test number 15. When I increased the frequency from 100 Hz to 125 Hz the tip held much better. I have not totally figured out the AC welding but this is my first time welding aluminum, so hope it will improve some as I figure out this welder. Sorry that the rows are inline, I had them lined up but they shift over when the thread is posted.



    3/32 Thoriated Tungsten
    3/32 4043 Filler Material
    1/8 inch thick 6061 Aluminum

    Test 1 2 3 4 5 6
    Current Setting (A) 90 125 125 125 125 125
    Frequency (Hz) 140 100 100 100 100 100
    AC Negative Balance -10 -20 20 0 0 -10
    AC Negative Amps 0 0 0 -20 20 20
    Gas flow LPM 7 7 8 11 11 11
    Not en ugh power Burned up Tungsten lots of cleaning good bead needs more argon lot more cleaning narrow bead flat bead, less cleaning more cleaning, flat bead

    7 8 9 10 11 12 13 14 15
    125 125 125 125 125 125 125 125 125
    100 100 100 100 100 100 100 100 125
    10 -20 -15 -15 -10 -10 -5 -10 -10
    20 20 20 25 15 25 30 30 20
    11 11 11 11 11 11 11 11 11
    balled up tungsten tip not as nice as 6 little better not as flat lots of cleaning OK flatter and not as much cleaning balled up tip more cleaning balled tungsten holds tip best out of all tests performed today
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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    Last edited by DVA; 12-22-2011 at 06:07 AM.
    Miller 252
    PowerTig 250 EXT
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  2. #2

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    The rule of thumb for gas flow in litres is: cup size +1,,,,+2 max at higher amps like 200 amps and above. Checkout page 3 of the CK Worldwide tech spec manual.
    Some of those lies people tell about me, are true

  3. #3

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    Hold your tungsten 1/8" or less off the metal. It looks like it may be further than that.

    Besides the crack down the middle, 5 looks good. So does 12, but a little hot.. Maybe whatever you are doing (hard to tell with the offset..might try attaching it in pdf or converting to jpeg)...

    Are you pointing the tungsten? Try to find a setting that isn't balling.
    Last edited by performance; 12-22-2011 at 12:40 PM.

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