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  1. #1
    Join Date
    Mar 2009
    Location
    Akron, Ohio
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    53

    Default Aluminum battery box

    Just learned how to TIG a few months ago, starting to get more into aluminum now. Taught myself by watching videos on YouTube, haha. Using a Diversion 165 Tig, 1/4" aluminum.

    I made this box with some spare aluminum laying around and some pre-angled aluminum I picked up at the hardware store. This is the biggest aluminum project I have tackeled yet.

    Thoughts, constructive criticism, tips? All welcome here!








  2. #2
    Join Date
    Dec 2008
    Location
    Arizona
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    812

    Default

    FRom what I can see it looks OK, but the pics are too small to see much detail......or maybe it's just my eyes. I need to get a 72" monitor!
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  3. #3
    Join Date
    Mar 2009
    Location
    Akron, Ohio
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    Default

    Quote Originally Posted by nocheepgas View Post
    FRom what I can see it looks OK, but the pics are too small to see much detail......or maybe it's just my eyes. I need to get a 72" monitor!
    Click on them and they should enlarge.

  4. #4
    Join Date
    Jul 2008
    Location
    East Tennessee
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    613

    Default

    I think the beads that it appears you weaved don't look as good as the others you just dipped the filler in with out the weave.Otherwise I think your getting the hang of it pretty well.
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  5. #5
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    Mar 2009
    Location
    Akron, Ohio
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    Default

    Quote Originally Posted by Showdog75 View Post
    I think the beads that it appears you weaved don't look as good as the others you just dipped the filler in with out the weave.Otherwise I think your getting the hang of it pretty well.
    I agree 100% ... the only reason I opted to do the weave was mainly because I have never tried it before on anything (mild, or stainless).

    I dont think the welds that I did with just dipping look too bad though, for a rookie...trying for that stack of dimes look ya know, haha.

  6. #6
    Join Date
    Apr 2009
    Location
    Central Florida
    Posts
    197

    Default

    did you preheat or use helium in order to do 1/4 with the diversion?
    Diversion 165
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  7. #7
    Join Date
    Mar 2009
    Location
    Akron, Ohio
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    Default

    Quote Originally Posted by andyman View Post
    did you preheat or use helium in order to do 1/4 with the diversion?
    No preheating and its 100% argon.

  8. #8
    Join Date
    Mar 2007
    Location
    Deltaville, VA
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    2,239

    Default

    widersturbo,

    You did ask.

    Beads appear to be very consistent. That's good.

    You're exceeding the capacity of the machine. Beads are cold, with little penetration to the base metal. Was even more apparent in another of your photos, which showed a tubing weld (which I think failed).

    Properly welding aluminum 1/4" thick, and with the "mass" you're dealing with, requires more amps than the Diversion can put out. Preheating and argon/helium mixes can only go so far in "helping out" the welding machine.

    If it was your intent to be doing this type work on a regular basis, and want "quality welds", you should be thinking Sync 200/250 or Dynasty 200.

    Your technique seems to be coming along fine. You're just asking the machine to do something it was never intended to do.
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  9. #9
    Join Date
    Mar 2009
    Location
    Akron, Ohio
    Posts
    53

    Default

    Quote Originally Posted by SundownIII View Post
    widersturbo,

    You did ask.

    Beads appear to be very consistent. That's good.

    You're exceeding the capacity of the machine. Beads are cold, with little penetration to the base metal. Was even more apparent in another of your photos, which showed a tubing weld (which I think failed).

    Properly welding aluminum 1/4" thick, and with the "mass" you're dealing with, requires more amps than the Diversion can put out. Preheating and argon/helium mixes can only go so far in "helping out" the welding machine.

    If it was your intent to be doing this type work on a regular basis, and want "quality welds", you should be thinking Sync 200/250 or Dynasty 200.

    Your technique seems to be coming along fine. You're just asking the machine to do something it was never intended to do.
    I was actually wrong...it is 1/8" aluminum. I dont mind criticism, it helps me fix my problems, only to become better at what I am trying to accomplish.

    What tubing weld are you referring to?

  10. #10
    Join Date
    Mar 2007
    Location
    Deltaville, VA
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    2,239

    Default

    widersturbo,

    Photo was of a tube joint (looked to be about 90 deg). Popped up in the related images when I clicked on your first image to enlarge it. May not have been one of your's but it popped up when I clicked on your image.

    Regardless whether the material you're dealing with is 1/8" or 1/4", the beads still look cold to me. Almost as if you were melting the filler with the torch rather than letting the puddle do the work. Really apparent in the photo that showed the tab you welded on.

    When you're dealing with that much material (the mass of the plate) you're pushing a machine that has a 20% duty cycle at 150A.

    What amp output were you using if you don't mind my asking?

    PS: Went back and checked the photo I was talking about. Think the direct link to it is http://img442.imageshack.us/img4

    If that link doesn't work, try clicking on the left arrow down in the related images below your photo. Comes up for me on the 4th click.
    Last edited by SundownIII; 10-01-2009 at 06:40 PM.
    Syncrowave 250 DX Tigrunner
    Dynasty 200 DX
    Miller XMT 304 w/714D Feeder & Optima Control
    Miller MM 251 w/Q300 & 30A SG
    Hobart HH187
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    Hypertherm PM 600 & 1250
    Wilton 7"x12" bandsaw
    PC Dry Cut Saw, Dewalt Chop Saw
    Milwaukee 8" Metal Cut Saw, Milwaukee Portaband.
    Thermco and Smith (2) Gas Mixers
    More grinders than hands

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