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  1. #1
    Join Date
    Dec 2005
    Location
    East coast
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    206

    Default Settings help EN/EP Dynasty 350 Aluminum .125 wall

    I don't claim to be anywhere near top shelf, but these are geting the best of me..

    I lost my "perfect settings" about a month ago when I had a guy come in and do some welding, he was old school, changed them, and my settings are off. All my tungstons were balled, cups filthy, and collets overheated. I could maintain points for hours.. and had low/moderate consumable use.

    Material, All new, Extruded .125 wall 6061
    I like to run 140-150 Frequency
    70% Balance
    Soft Wave form
    Most of the time, I set amps at 250 and float the pedal. There are instances where I floor it with 350 to heat up solid 1.5 inch 6061 blocks to join to the .125 wall, but pre-heat those to 250 degrees as well.

    Have a flex head torch with interchangable heads, so I do switch out the heads when I do the big runs, but usually keep a small head on it and just soak up the consumable cost as I can't get in the tight spots with the bigger ones.

    4043 wire, 3/32 as well as 2% ceriated
    18-20 CFM 100% Argon
    #8 Cup, no gas lense
    Most of the time never hit the material with a SS wire brush, but as I get 2000 lbs at a shot, starting to see some oxidation, so I do..

    I've narrowed what I think my problem is down to the EN/EP settings.

    Reasarched and read some views on the subject, but with a limited ammount of time, cannot nail them down. By ear, I know it does not sound the same, but don't know what direction to move in..

    Alum guys, your help would be very welcome.

    Thanks
    Last edited by Checkered Flag; 11-16-2010 at 01:00 AM.
    Two Dynasty 350's with Wireless pedals
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  2. #2
    Join Date
    Dec 2005
    Location
    East coast
    Posts
    206

    Default

    Also, I do usually get the 5356 sticks, but gust got stuck with 4043 (40lbs)

    Would that cause this?

    It's like a skin forms and I can't outrun it no matter how fast I go.

    Low, high amps, moving fast or slow, seems Like I'm just feeding a blister and having contamination and sub-par apperance.

    Thanks
    Two Dynasty 350's with Wireless pedals
    Victor O/A
    Profax 250 weld positioner
    Bridgeport mill
    Logan Turret lathe
    RMD tubing bender
    Enco vertical saw
    Baileigh Auto cold saw
    IR 80 Gal dual stage compressor
    Misc Fab equipment

  3. #3
    Join Date
    May 2008
    Location
    Mpls, MN
    Posts
    464

    Default

    I would start by setting it at 50/50 (or what ever to make them equal) just like a dynasty 200 or any other welder without that adjustment. Then I would look at turning up your balance because on new clean parts you should be able to run up to 80%. I seldom drop below 75% even on dirty castings.

    You mentioned that you don't always wire brush the parts (no crime there, I don't always either). But are you at least wiping them down with a solvent rag (acetone, lacquer thinner, alcohol)?

    -Dan
    Owner
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  4. #4
    Join Date
    Sep 2009
    Location
    South Carolina
    Posts
    570

    Default

    I had something set bad once. Could not get things back no matter what. I done the default reset on start up and started over.

    Never knew what was wrong but after the reset, things were back to normal.

  5. #5
    Join Date
    Feb 2009
    Location
    Maryland
    Posts
    707

    Default

    The machine has so many settings....
    By no means optimal, it just seems to work for me:
    Soft square. Typically balance 80% EN, maybe 80-100Hz (I like lower frequencies better). EP to EN at 75%. This leaves a very narrow cleaning strip. At about 85% it disappears. In the flat, I set the amps for a bit more than the 1Amp per .001. So for 1/8, I would dial in 140 and throttle it with the pedal. I rarely give it full power - probably 80%. I seem to recall my daughter saying 111Amps - reading from the display. I'm using the arc zone rare earth tungstens. Didn't like the ceriated ones from Miller because the orange paint was so thick it wouldn't slip past the collet. I don't have enough experience with other tungsten on Aluminum to compare. The tip stays remarkably pointed all the time.

    I've tried various settings with pulse but it seems best just to turn it off. I think I can see the puddle quiver, it just doesn't seem to do any good. More experimentation needed.

    I always clean with wire brush (dedicated stainless steel one) - on clean aluminum I sometimes don't use chemical cleaner. I get better arc starts with smaller tungsten - so I always pick the smallest for the amp range.

    How's that?
    Con Fuse!
    Miller Dynasty 350
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  6. #6
    Join Date
    Dec 2005
    Location
    East coast
    Posts
    206

    Default

    Ugg, I'm just depressed, can't get back on track at all... Have to get this solved, now I have a backlog of a certain part done on pulse with a rotary table that, if wrong, costs 3-400 dollars each failure..

    Now that I think of it, I've no idea what my dedicated SS wire brush was used for while that guy was there, probably cleaning files and lawnmower blades for all I know.

    Will hit it again tomorrow, Much more, and I'm doing the factory reset and working from there.

    Thanks
    Two Dynasty 350's with Wireless pedals
    Victor O/A
    Profax 250 weld positioner
    Bridgeport mill
    Logan Turret lathe
    RMD tubing bender
    Enco vertical saw
    Baileigh Auto cold saw
    IR 80 Gal dual stage compressor
    Misc Fab equipment

  7. #7
    Join Date
    Oct 2008
    Location
    Honolulu, Hawaii
    Posts
    22

    Default

    Just my 2 cents but adjusting EN/EP independently would be to help with cleaning and or tungsten life. I messed around with it for hours in the past and ended up back to an equal setting on both unless I am welding some crazy thick pieces. Im not entirely sure what it is you are putting together but I have welded alot of the same tubing to similar sized blocks with the following settings: 78 bal, 145 freq,220 amps, soft wave, 3/32 throriated, w/foot pedal. The welds looked awesome to me but it wasn't a NASA part. In regards to the 4043 it should provide you with a more aesthetically pleasing weld. it just wont be as strong as the 5356. I know what you mean about not finding the same sound or perfect settings. I write them down on blue painters tape stuck to the side of my machine. Good luck!
    If you don't expect anything you wont be disappointed.
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  8. #8
    Join Date
    Aug 2010
    Location
    Los Angeles
    Posts
    1,168

    Default

    Here are some of my program settings.

    Program #1, thick castings and alum plate;

    Advanced Square wave
    EN 349
    EP 262
    Balance 80
    AC Freq. 80



    Program #2, 1/8 alum and up;

    Soft Square wave
    EN 250
    EP 200
    Balance 75
    AC Freq 100



    Program #3 (factory default), 1/8 alum and under;

    Soft Square wave
    EN 150
    EP 150
    Balance 75
    AC freq 120

    I have not produced a program #4 yet which I will try to tune for super thin, as I will pull up the Tri wave profile, and probably equal polarity, and balance of 60% and AC freq of 150. My old Linde 305 still fills that role.
    Last edited by shovelon; 11-17-2010 at 10:57 AM. Reason: spelling
    Nothing welded, Nothing gained

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  9. #9
    Join Date
    Feb 2009
    Location
    Maryland
    Posts
    707

    Default

    Quote Originally Posted by hawaiiweld View Post
    I know what you mean about not finding the same sound or perfect settings.
    Funny how much sound has to do with it. I think that's mostly why I'm more comfortable at lower frequencies - like 80Hz. I doubt it was anything I saw in the puddle (Quite frankly don't have enough experience to make that call)
    Con Fuse!
    Miller Dynasty 350
    Millermatic 350P
    -Spoolmatic 30A

    Hypertherm PowerMax 1000G3
    Miller Multimatic 200 - awesome portable MIG (and stick and TIG)
    Miller Maxstar 200DX - portable TIG and stick

  10. #10
    Join Date
    Dec 2005
    Location
    East coast
    Posts
    206

    Default

    Quote Originally Posted by con_fuse9 View Post
    Funny how much sound has to do with it. I think that's mostly why I'm more comfortable at lower frequencies - like 80Hz. I doubt it was anything I saw in the puddle (Quite frankly don't have enough experience to make that call)
    It's the sound to me, I hit that ultimate "sweet" spot and churned out these welds on a daily basis Crisp, clean, and well, just about perfect..
    Attached Images Attached Images
    Two Dynasty 350's with Wireless pedals
    Victor O/A
    Profax 250 weld positioner
    Bridgeport mill
    Logan Turret lathe
    RMD tubing bender
    Enco vertical saw
    Baileigh Auto cold saw
    IR 80 Gal dual stage compressor
    Misc Fab equipment

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