hi everyone, i'm happy to say that the latest test was successful.

here is the sample weld bead..
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here is #17 torch before welding showing the stick-out
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#17 torch after welding. looks clean, no balling up
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#9 torch before welding
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#9 torch after welding
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looks like the galvanized aspect is the issue after the pure argon issue.

thanks everyone for your inputs.

onwards to weekend, i will try the AC on aluminum and stainless steel. because i have projects as well involving these two metals. in fact, i will be needing one distinct feature of the 255ext which is the spot weld. how good can it be in stainless steel? i have to spot weld solid stainless steel rods to each other at certain bends. i will post that project once i've finished it. it won't be soon though.

anyway, i'll update this thread again for the weekend testing on aluminum and stainless steel....

thanks again.