Question about Miller SYNCROWAVE 250 DX TIG RUNNER WELDER 951117

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The water hose keeps bursting while welding aluminum

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  • Ron Jones
    Ron Jones May 11, 2010

    Which hose - on the torch on the the pump or another location ?

  • Robert Lee May 11, 2010

    does the pump run

    is water flowing back into the tank when the pump runs

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  • 92 Answers

The probable caures is due to the coolant pressure, do'nt turn this full on, if it's from the mains tap turn on and notice a trickel from the outlet, one half turn of the tap should be ok depending on the water presure. If its from a recirculation tank check the vale govener inside the tank. The torch data will indicate the coolant pressure

Posted on Feb 27, 2009

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What polarity do I use for tig welding aluminum, and what color electrode for miller hf-p dial arc


Jackie, watch the linked videos on tigging aluminum. "I hope this helped you out, if so let me know by pressing the helpful button. Check out some of my other posts if you need more tips and info."

May 31, 2016 | Miller TIG Welders

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How to set up welder or aluminum tig welding


If you want to weld aluminium with a welder, your machine must be an AC/DC welder, then you will use only AC to do the weld, but as well you must have a contineous high frequency and according to what thickness you want to weld a water cooling argon torch wont be a luxury

Aug 25, 2014 | TIG Welders

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I have a ranger 305d how can i set it up to weld aluminum?


You may not be able to unless it is DC voltage You need the special rods for welding aluminum but my understanding is it takes a DC welder to use them.

Mar 11, 2013 | Lincoln Electric Ranger 305D K1727-2...

1 Answer

The F 1 circuit breaker, manual reset is tripping not allowing it to weld. Could it be something as simple as the reset itself


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 :
-The material of the job
-And the proper amperage to use for the material.
-For aluminum you will use A/C
-Stainless Steele / Chrome Molly D/C

Aluminum MIG Welding
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 have a Miller Synchrowave 180 sd and have been having difficulty welding aluminum. Can you please help.


I'm not sure what it's doing to know why it's not working but if I was trying to weld aluminum I use 100% argon in ac with high frequency continuous and a 9 second post flow with 5356 crown weldind rod.

Jun 05, 2010 | Miller TIG Welders

1 Answer

I have a miller microwave 200. what settings should i use for aluminum welding? dcep, ac, dcen? i'm using a3/32'' tungsten and trying to weld on 1/4'' alum plate. the weld is not turning out to be a smooth...


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.

Now - these are just generic settings, but they will get you going.

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1 Answer

How to prepare tungsten for aluminum for welding aluminum a ball is supposed to be fashioned on the tip of the tungsten electrode how?


To make successful aluminum welds you must set your TIG machine to A/C, so make sure you get a tungsten rod meant for running alternating current. If it is pure tungsten (green band on the end), you're good. For the tip, just grind a tip like you normally would. When you start welding a bit of aluminum will collect on your electrode. After that you may need to break off the tip every now and then if you get a lot of junk in the ball. Make sure you practice on some scrap first, aluminum is very different to run than other metals. Getting the right operating temperature down is a bit trickier too.

Just in case you're working on something serious like a motorcycle frame, make sure the aluminum you're using is a grade that's able to be welded. I've heard about a guy that built costom bikes and used the wrong grade, when the customer took the bike down the highway it fell apart on him.

Aug 05, 2009 | TIG Welders

2 Answers

Welding aluminum


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

Dec 22, 2008 | Miller Electric Manufacturing Electric...

1 Answer

TIG welder help


Choose the electrode to use for the project you are starting as well as the variety of alloys you'll use such as the 6061 Aluminum alloy electrode. Grind the electrode to a point. Try to create a tip and sharpen it to help it become more rounded as you weld. Place the electrode into an electrode holder with the tip about 1/4-inch away from the sheath. Choose the settings on your tig welder. The three main ones are AC, DCEP and DCEN. Choose AC for aluminum. Slide the "cleaning/penetrating" slider more to the penetrating side. Set the "air on" to five seconds and the "max amps" to 250. Turn on the gas. For aluminum, use pure argon. For steel, an argon and carbon dioxide mix. Scrub your welding table or flat piece of sheet metal with a wire brush to make it clean and flat. Gear up in full welding safety gear including hood, goggles, apron and gloves. Hold the electrode in your dominant hand and start your welding project. Check your settings every so often to make sure they haven't changed and adjust as needed.

Aug 27, 2008 | Miller SYNCROWAVE 250 DX TIG RUNNER WELDER...

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