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welding aluminum beer cans

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  • #16
    I wouldn't think so because it's probably not a cleaning issue... the deal is that since the base metal is so thin, he can't get it much above the melting point without blowing a hole in it, so when he dips the rod in, it sucks enough heat from the weld pool to teter on the phase change. It's basically trying to solidify on him and has little if anything to do with dirt.

    80% of failures are from 20% of causes
    Never compromise your principles today in the name of furthering them in the future.
    "All I ever wanted was an honest week's pay for an honest day's work." -Sgt. Bilko
    "We are generally better persuaded by reasons we discover ourselves than by those given to us by others." -Pascal
    "Since we cannot know all that there is to be known about anything, we ought to know a little about everything." -Pascal

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    • #17
      As "Beer Can Moderator", I will delete any future posts where the thread starter claims to even try to weld cans together, when the post doesn't include pictures. Sorry, guys.

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      • #18
        Originally posted by spotsineyes View Post
        As "Beer Can Moderator", I will delete any future posts where the thread starter claims to even try to weld cans together, when the post doesn't include pictures. Sorry, guys.
        I will post pics of my progress as soon as i get back from eating (leaving in 5 minutes)... like i said, i still burned a few holes, but it's my best progress yet.
        Dynasty 200DX
        Hobart Handler 135
        Smith MB55A-510 O/A setup
        Lathe/Mill/Bandsaw
        Hypertherm Powermax 45
        Just about every other hand tool you can imagine

        Comment


        • #19
          I didn't do so well and the fumes were terrible. I need help. What amps and balance?

          James
          Miller Dynasty 200DX SOLD
          WeldTec Water Cooler SOLD
          Miller Millermatic 180 w/ Spoolmate 100
          20Ton press
          And lots of Cut-off and grinding wheels
          www.IAGPERFORMANCE.com

          Comment


          • #20
            Originally posted by StillBoostin View Post
            I didn't do so well and the fumes were terrible. I need help. What amps and balance?

            James

            I've used between 20 and 30 amps (with a tig start amperage of 10A and starting on EP) ..the better i get the more towards 30amps i stay. Balance is at 60% EN no matter what, I've used both 40-60hz range and up to right around 140-150 but it was more diffiult and required more torch manipulation. 40-60 was best. You must clean the cans REALLY good, you will see the oxide layer and something else come off and the metal will get shinier (not sure what all it is but scotch brite worked better than a wire brush) Start with the rod in the groove as soon as your arc strikes, then keep filling the puddle continuously while moving the puddle..dont' take the rod from the puddle at all!!!

            I've done it with and without the pulser...the settings i use on it are.
            30Amps
            15PPS
            80% peak
            10%background

            Using 1/16th tungsten (ceriated and thoriated) and 1/16 4043 filler rod.. I'm only burning holes when re-starting the puddle after turning the can to re-position for welding...a few weeks ago it was 3/16ths of sloppy bead and 1 1/2 inches of holes then another 1/8th bead LOL I put a pic of an older red-bull can i did about 2 weeks ago in my new thread in the project section
            Last edited by turboglenn; 09-29-2008, 11:40 PM.
            Dynasty 200DX
            Hobart Handler 135
            Smith MB55A-510 O/A setup
            Lathe/Mill/Bandsaw
            Hypertherm Powermax 45
            Just about every other hand tool you can imagine

            Comment


            • #21
              Delete this

              I have done this with my Syncro @ 10 amps, no pulse, .020 gold band tungs sharpened to a semi pencil point with a flat(magnifying lens required), .020 gas lens.


              Heres a couple of hints:

              Clean the crap out of the cans, they have a lacquer coating. Use MEK or acetone first, then stainless brush.
              Don't try to weld the tops, there is an adhesive sealant between the top and the can, which gives off gnarly fumes, and the smoke contaminates the weld. Maybe if I had a smaller cup I would try the tops again.

              The wall thickness is around .007 , slightly thicker at the base, so setup accordingly.

              I will have pics of this.

              OK HERE IT IS:
              http://i100.photobucket.com/albums/m...5/DSC00356.jpg
              notice the nice weave, open root gap of about .040 and I had to use 18 amps this time.
              the burn holes are from where it was grounding. Not my best, but I had just come from the gym and my arms were smoked, and I had Mississippi Delta mosquitoes trying to drain me/carry my filler rod off.....I guess cause its shiny
              Last edited by Blackbird455; 09-30-2008, 06:38 PM.
              SYNCROWAVE 200
              Atlas 618 lathe (vintage 1960) reconditioned DC
              Sioux 3/8 Pneumatic Reversible Drill
              Makita Everything else
              2400 square feet of Sanford and Son lookin shop space
              "Once the spoon flys, putting the pin back in won't solve anything"
              USA 15T, 15V

              www.myspace.com/blackbird455

              http://i100.photobucket.com/albums/m...5/DSC00356.jpg two cans, one welder

              Comment


              • #22
                Look up there

                Yeah I dont know why I edited that one instead of a new post

                http://i100.photobucket.com/albums/m...5/DSC00356.jpg

                see description above
                SYNCROWAVE 200
                Atlas 618 lathe (vintage 1960) reconditioned DC
                Sioux 3/8 Pneumatic Reversible Drill
                Makita Everything else
                2400 square feet of Sanford and Son lookin shop space
                "Once the spoon flys, putting the pin back in won't solve anything"
                USA 15T, 15V

                www.myspace.com/blackbird455

                http://i100.photobucket.com/albums/m...5/DSC00356.jpg two cans, one welder

                Comment


                • #23
                  Very nice work blackbird! Someday i will get them that smooth as well.. Any specifics on your setup, tung size, filler alloy and size...balance, freq. etc..???
                  Dynasty 200DX
                  Hobart Handler 135
                  Smith MB55A-510 O/A setup
                  Lathe/Mill/Bandsaw
                  Hypertherm Powermax 45
                  Just about every other hand tool you can imagine

                  Comment


                  • #24
                    .020 gold band tungsten, semi sharp, 12 cfh, #4 cup balance was set to 8.0 (syncrowave 200 setting) 18 amps, no pulser.......uhh and two miller lites oh 5356 1/16 rod cause it was two feet closer to me than the 4043.
                    Last edited by Blackbird455; 09-30-2008, 07:20 PM.
                    SYNCROWAVE 200
                    Atlas 618 lathe (vintage 1960) reconditioned DC
                    Sioux 3/8 Pneumatic Reversible Drill
                    Makita Everything else
                    2400 square feet of Sanford and Son lookin shop space
                    "Once the spoon flys, putting the pin back in won't solve anything"
                    USA 15T, 15V

                    www.myspace.com/blackbird455

                    http://i100.photobucket.com/albums/m...5/DSC00356.jpg two cans, one welder

                    Comment


                    • #25
                      does 5356 make it any easier or harder than 4043? ONce again i must say, very well done..you got skills!
                      Dynasty 200DX
                      Hobart Handler 135
                      Smith MB55A-510 O/A setup
                      Lathe/Mill/Bandsaw
                      Hypertherm Powermax 45
                      Just about every other hand tool you can imagine

                      Comment


                      • #26
                        I really am not sure, but I think the 5356 wets and flows better.......could just be unfounded, but it really flowed good, and followed the heat and keyhole nicely. It also transferred the heat to my left hand efficiently, mainly because I never pulled it out of the keyhole.
                        Thanks for appreciating my work!!! I have only owned that Syncro since Feb, and so the bulk of my TIG time has been since then. I even had a 2 month break June-July cause I had too much stuff going on to weld.

                        I have been doing alot of practice on open root pipe here lately, and also thin < .032 aluminum, so I guess it has paid off. Like I said, thats not even my best, I did that on my low table, low chair, as opposed to my high table and standing. I'm gonna better that one though, and get comfortable, use my rotary ground connection, and then take pics with a new Olympus 10+ megapixel, to get better detail.

                        I still aspire to weld a bead like I used to look at daily on the T63 Allison turbines combustion section, It had to be robotic. Absolutely perfect in every way. Maybe one day.

                        So maybe I will have more pics in a week or so, have to go get some more
                        "1006" or "green gas".

                        Also I am going to try .040 tungs sharp point next time, the .020 would ball right about 18 Amps, causing more cleaning, but less wetting-puddling.
                        Last edited by Blackbird455; 09-30-2008, 09:03 PM.
                        SYNCROWAVE 200
                        Atlas 618 lathe (vintage 1960) reconditioned DC
                        Sioux 3/8 Pneumatic Reversible Drill
                        Makita Everything else
                        2400 square feet of Sanford and Son lookin shop space
                        "Once the spoon flys, putting the pin back in won't solve anything"
                        USA 15T, 15V

                        www.myspace.com/blackbird455

                        http://i100.photobucket.com/albums/m...5/DSC00356.jpg two cans, one welder

                        Comment


                        • #27
                          Challenge

                          Ok so I put my cash where my beer hole is...........

                          How about the rest of you?? We need some more pics!!!

                          I want to see what some of you with inverter machines, that have 10x the settings of my humble Syncro 200 has, can do.
                          SYNCROWAVE 200
                          Atlas 618 lathe (vintage 1960) reconditioned DC
                          Sioux 3/8 Pneumatic Reversible Drill
                          Makita Everything else
                          2400 square feet of Sanford and Son lookin shop space
                          "Once the spoon flys, putting the pin back in won't solve anything"
                          USA 15T, 15V

                          www.myspace.com/blackbird455

                          http://i100.photobucket.com/albums/m...5/DSC00356.jpg two cans, one welder

                          Comment


                          • #28
                            No Replies? What????

                            Come on, someone has to have some pics.
                            SYNCROWAVE 200
                            Atlas 618 lathe (vintage 1960) reconditioned DC
                            Sioux 3/8 Pneumatic Reversible Drill
                            Makita Everything else
                            2400 square feet of Sanford and Son lookin shop space
                            "Once the spoon flys, putting the pin back in won't solve anything"
                            USA 15T, 15V

                            www.myspace.com/blackbird455

                            http://i100.photobucket.com/albums/m...5/DSC00356.jpg two cans, one welder

                            Comment


                            • #29
                              I"ll get some pics of mine up soon... problem is I"ve been working late on a home re-paint and when i get home to my mini-lab the wifey is already there and she absolutely hATES the sound of AC welding so i try and not do any here if i don't have to.... Of course when i'm not here i'm working on paying projects and don[t have time to mess with cans... I'll get some up this weekend though
                              Dynasty 200DX
                              Hobart Handler 135
                              Smith MB55A-510 O/A setup
                              Lathe/Mill/Bandsaw
                              Hypertherm Powermax 45
                              Just about every other hand tool you can imagine

                              Comment


                              • #30


                                Nothing to brag about, but I can see how it will be pretty easy with practice (and a Dynasty).

                                Scuffed up the ends of the cans, but I could hear the Coke boiling inside. Also, whatever is burning off the cans is pretty strong...got a little buzz.

                                3/32 Tungsten (too big)

                                1/16 5356 filler

                                35 amps

                                Pulse...200+pps I think, 80 and 40 the other settings.

                                60 balance 60 hz.

                                Starting was a little messy (big tungsten) but I could leave the heat on there for a long time.

                                I had the two cans setting on a piece of strut to align them, thus the burn thru marks.

                                -James

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