Question about Miller Electric Manufacturing Electric Syncrowave 250 DX TIG 907194032 Welder

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Welding aluminum Dirty and poros weld on ac when welding aluminum.

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Assuming that you are familiar with Tig welding anyhow, and are using Argon gas and have made sure that your fittings are snug on both ends of hose (don't forget there is a fitting at the rear of you torch accessible by gripping and sliding handle back), and that your ceramic nozzle is also snug let's get you welding aluminum. First off never weld aluminum (or anything else really once you try them) with collets and collet bodies provided with torch, replace those with Gas Lenses and Nozzles and a gas lense insulator. You can get away with green or red tungsten, with a gas nozzle you can now turn your flow down to 20-25. As with previous post, CLEAN is #1 use clean stainless steel brush with WOOD handle not plastic, I choose to stay away from chemical cleaners. Now with a ball on your tungsten make sure you make a cleanup/heatup pass of area you are welding til there is no black stuff (contaminants) before adding any filler rod. Go ahead make a pool, add filler at your hearts content....WOW like night and day!

Posted on Apr 22, 2009

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TIG weding is next to brain surgery as far as CLEAN goes.
You must get your AL clean, either by 1. Clean with a NEW Stainless Steel brush or 2. by using a chemical from the welding house that is made just for that.
Your cup must be clean and your gas flowing at the right amount,no leaks in o-rings or hoses.
Hold your cup more vertical and keep your filler rod in the gas shield always,no in and out movement.
In short you must get everything perfect to get quality Heliarc Al welds.
Good luck, HowardRoark

Posted on Dec 28, 2008

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Lincoln precision tig 225. Makes bad aluminum welds in AC. Welds show signs of contamination. Have tried new argon bottle. No leaks in gas lines. Using pure and 2% thoriated tungsten, 3/32, pure...


Hello; Make sure AC Auto Balancing is Enabled; And when Welding Aluminum Aways use 100% Pure Green Coded Tugsten.Make Sure you dont have 75/25 or possibly if you know for sure your frequency balancing on your machine is working you could possibly have a bad bottle of gas try the bottle of gas on the machine that you say that runs good if it runs good put it back on the 225 if the problems still exist there is something wrong with your machine`s Ac high freqency Auto Balancing.Make sure all connections are good,check tig head for loose connections. Step Up to A 1/8 size tugsten it will carry more heat and gets less contanimated.Every time you stick your tugsten it will run contanimated untill you burn it off or clean it ,if you stick you tugsten go ahead and put a clean piece back in the tig head, Contanimated tugsten wil run dirty for 5 to 20 minutes Untill you BURN it Back Clean !?

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Rated Output at 20% Duty Cycle 150 A at 16 VAC
150 A at 16 VDC Welding Amperage Ranges AC/DC 10 - 165A Max. Open-Circuit Voltage 80 V Amps Input at Rated Output AC-230V: 21A
DC-230V: 23A You need to configure the machine to specifications of the material you going to weld.That is :
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1. The best feeding of wire for aluminum is done with a spool gun. If you can't use a spool gun, use the shortest gun possible and keep the gun as straight as possible. Use Argon only for shielding gas. Only use a push gun technique when welding aluminum. 2. If you are having feeding problems, one thing you can try is a contact tip that is one size bigger than your wire. 3. The most common wire type is ER4043 for all-purpose work. ER5356 is a stiffer wire (easier to feed), and is used when more rigid, higher-strength weld properties are needed. 4. Clean the aluminum before welding, to remove the oxide layer. Use a stainless steel wire brush used only for cleaning aluminum. 5. Fill the crater at the end of the weld to avoid a crack. One way to do this is to dwell in the weld pool for a second at the end of the weld.
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I think you mean you have a Miller Synchrowave 200.

Typically, you would want to use AC below about 250 amps. In this case (to keep it simple), use AC, adjust your balance to about 4, use an 1/8" pure tungsten, pure argon at about 20CFh, and set the panel at 170amps to get things started. For general purpose, use 4043 filler.

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