Quote Originally Posted by Deep Six View Post
Additional info:

I was previously having problems with porosity in ground, clean A36 steel. NOT galvanized anything. I solved the porosity issue by using stainless 309 filler. I was also having some success using going slow and jamming as much ER70S2 filler as I could manage into the weld. However even the steel welds have a dull grey appearance that can be wire brushed to a nice shine.

I did try cleaning settings between 20 - 80%. 20% gave me more black goo and 80% gave me a giant ball on the tungsten and no penetration, as expected.

I think I'm better than halfway thru the 55cf tank of gas. So soon enough I'll have a fresh tank of gas to try.
Ok, I just wanted to make sure your balance control was working properly. Check, that is as expected.

For learning I would advise larger pieces of material, that way the heat won't get out of control so easily. Also cool off the material between welds. For practice you can just dunk them in water, but don't do that with actual projects. Also ensure that it is totally dry before trying another bead. From what I can see your arc length looks to be on the large side. Rule of thumb, try to hold a max arc length about one tungsten diameter. To do this you will have to lift the torch as you add filler then lower it as you move forward. Trying to jump right into aluminum is a big challenge. When I have taught new employees to TIG, I typically start with 1/8" steel then wait until they semi master that before moving to 16 gauge sheet steel. Where upon the welds go back to looking like crap but they get that pretty quick. Once they master the sheet metal and start getting cocky. I bust out the 1/8 aluminum and take them down a peg or two. Their welds go back to looking like crap, but they understand the fundamentals and have a pretty good idea what they are doing wrong, just not enough control to prevent it. That just takes practice. However, everything you learn about aluminum will make steel a cake walk. Once you can lay a good bead on 6061, you can weld steel standing on your head. Previous MIG and stick welding skills never made much of a difference. If anything they had bad habits from other processes. The only person I taught that got it quickly was someone that had done a bunch of oxy-fuel welding many years before. And while watching videos is a great new way to learn, it probably won't be as fast as someone looking over your shoulder, saying more pedal, less pedal, too long, don't starve the puddle, add filler, get moving, etc. It just takes practice.