Aluminum welding advice

[Kpaige]

I want to get a tig welder capible of welding aluminum.
I get alot of contradicting info so thought I would post here.
I dont plan on using this alot and it will be used on thin aluminum mostly 18-20 gauge with some occasional flat stock 1/8-1/4 but very minimal.

I have welded with a spool gun and really dont like it.

I do not want to spend a crazy amount. Want just the basics to get the job done with no frills.

Can run 110 or 220

What do I need minimum to start

And what is an adequate unit?

 

[dr_clyde]

My vote is for the Lincoln SW 200. $1500 out the door and welds aluminum great.

Minimum you'll need a welder (obviously), filler wire and shielding gas. Having the welder assumes you have tungsten, cups, and gas lenses/collet bodies.

You want 1/16" 4043 rod, 3/32" ceriated or lanthanated tungsten, and a #8 or so cup. Pure argon. 20cfh on the flow meter.

 

[BFHtime]

Check out millerwelds.com they have a forum over there that will tell you all you need.

 

[ItsNemo]

Needs to be an AC/DC capable TIG with enough output to deal with the thickness you plan to weld. Not much more to it than that. The Lincoln SW200 is pretty well best bang for the buck in AC/DC tigs out there right now.

 

[kkroger]

AHP AlphaTIG200X does what you need to do has features that the bigger ones have for less than half the cost of the Lincoln... Has some faults... the Pedal being the number one part but add a hundred dollar pedal to the cost and you are STILL less than half, comes with a true flowmeter not a flow regulator like the Lincoln... And you CAN weld aluminum on DC... it is just easier and a bit cleaner on AC.... the AlphaTIG 200 is $680 plus $30 shipping on Amazon the NOVA pedal is $99 shipped on Amazon... My Home AHP with Water Cooler and 20 torch is STILL less money than the SW200....

 

[txvwnut]

What he said^^^^^ except I went with a SSC Controls pedal for mine. You can’t go wrong with an Alphatig.

 

[kkroger]

What he said^^^^^ except I went with a SSC Controls pedal for mine. You can’t go wrong with an Alphatig.

Actually I have two of these machines the one pictured here has an SSC pedal the one at the shop has a Nova pedal, Functionally there is no difference, the SSC pedal has a Pot made in Mexico, the NOVA has a pot made in Japan, the steel housing is identical the gearing is identical, the cable and strain relief are identical and the SSC heel rest fits the NOVA pedal exactly like the SSC. The AHP units have standard DINSE 35 connections and a 9mm QD gas fitting. I got my cooler from HTP I paid more it has an Italian Pump and Copper radiator there are Chinese ones that have a Chinese pump and Aluminum Radiator... (the radiator is basically a double row transmission cooler style coil) the tank is a poly tank... All in all I love my little AHP. if/when it dies I'll replace it with an HTP which is a STEL Italian machine which with cooler etc is still cheaper than a Dynasty. the AHP is WAY cheaper than the Miller Diversion 180 and vastly more features... a 60% Duty Cycle at 200A on TIG and 100% at 155A and below.

 

[dr_clyde]

Fwiw, support from your local welding supply can be a huge benefit. Ask them what they recommend you get for your budget and if they can service them. Sometimes it's worth a few extra bucks to get a machine that is easy to get parts and accessories from the local guys.

 

[kkroger]

Fwiw, support from your local welding supply can be a huge benefit. Ask them what they recommend you get for your budget and if they can service them. Sometimes it's worth a few extra bucks to get a machine that is easy to get parts and accessories from the local guys.

Definitely true, so ESAB, MILLER or LINCOLN... I had a Diversion 180 not an IDEAL TIG but very simple to use. One knob one button either AC or DC, etc etc etc.. over $2000 and doesn't do what that AHP will do. I am a dyed in the wool MILLER fan... when I got my diversion I couldn't afford a Dynasty and I ALMOST got a Synchrowave 210.. but it was not really a "GREAT" machine either I still would take a Dynasty if I had a chance (Saw a TIG RUNNER kit with cooler, cart etc etc for $4k used... lightly and didn't have the scratch at the time) we got the AHP at the shop and I used it heavily for over 6 months getting to know it, then I bought my personal one... my Diversion freaked out and decided to start welding on its own, gas was off, Machine was OFF, suddenly fired the torch (it was laying on the welding table) Fried most of the boards in the machine, Miller replaced the machine... but not the pedal... the PEDAL was the issue on that box too... but the warranty on the pedal was 1 year, the machine 3... so now I have a box with no pedal... YAY!


Back to the business at hand, building a rapport with your LWS is advantageous in a lot of ways, you will have to buy GAS, and a BOTTLE (don't buy a new one it is useless just get one at the LWS and call it a day) I keep 2 80s of Argon, 2 of 75/25 and a 40 of each at home, I have 330s at the shop, You will need Tungsten, Filler metal, Cups, Collets, Gas Lenses, collet bodies, Back Shells (things get broken when you least expect it) consumables for your hood, Gloves, All that stuff... the LWS many times if you build a relationship (and you are gonna go through some gas learning!) sometimes they will give you a few samples of filler metal and tungsten to try out. get a good relationship built and you WILL get discounts on stuff. I buy Plasma Consumables there, I buy Gas, I buy Gloves I buy cups and so forth... I get really good deals there. I just e-mail my counterman and he puts the stuff back for me and I go by and pay with my personal card when I have time, or they bring it by the shop when they make a delivery.

I have started using Blue Demon Filler metal instead of harris lately so I get it online, I use Midwest Tungsten Service Tungsten... but Ck Collets, Collet bodies, Cups Lenses etc for the torch are best bought locally... Just get the damned 4 packs of cups and such they are CHEAP. get a compartmented Plano box from Wally world to sort your stuff, Use Wedge Collets, I use 3/32 Tungsten for everything I just sharpen differently... 2% Lanthanated, I use 3/32 Aluminum Filler for pretty much everything too, 5356 mostly but I keep 4043 on hand as well. 308L and 70S2 I keep 1/16 and 3/32....

 

[Kpaige]

Thanks for the help and guidance.
I should have been clear on my intentions. This is a budget beginner will be doing hobby stuff and the machine will get used in spurts. Mosstly on aluminum and stainless. I wish I had the budget to go with a big name but I do not. I am looking to go with very enry level so here are my three choices
Vulcan protig 200 (899)
2018 AHP 200X (759)
Eastwood tig 200 (729) ( not digital)

All are low line budget machines
I think the eastwood is a no go it has no setable cleaning freq is is set at 60%, and it has no pulse benifet of it is eastwood is pretty good at standing up to their warranty

The protig from everything I can see and read is a good solid machine for the hobbiest ( me) lical stores but more money comes with all the basic stuff and has most functions you would need.

Then AHP
It by all means looks the most impressive has more functions then the others. Ahp is an American company so easier then speaking chinese. Comes with most of what you need
Price is good and includes shipping. Read mixed reviews but they are all older 2014-2015.

Out of those machines thoughts?

Tungsten and filler question

I will mostly be welding aluminum 1/8 to 1/8, 1/4 to 1/4 but I will also be welding 18 gauge to itself and 18 guage to 1/4
What cup sizes, tungsten, filler?

For stainless its art stuff for the wife like spoon art flowers, birds etc
hat cup sizes, tungsten, filler?

With all that said I am making a trip today to the LWS to talk to them chances are slim they eill have sonething but it is well worth a shot. Any input is greatly appreciated!!!

 

[kkroger]

The AHP is a Chinese machine (offshoot of Everlast) they seem easier to deal with. Like I say I use two different AHP AlphaTIG machines daily, it is 680 on amazon and about $30 shipping so 710 ish... Do yourself a favor and get the NOVA pedal while you are at it, that is $99 shipped also on Amazon. I'll post the links, I use 3/32 tungsten just sharper for thinner stuff more blunt for thicker, BIG cups for Stainless and smaller for Aluminum. Get some Gas Lenses, Again I only use 3/32 tungstens so I only have to buy one size lens and one size collet, get WEDGE collets (this is all Ck products but others have them as well)

 

[Balor]

Go with the Everlast Powertig200DV. You will be glad you did.

rngr1

 

[Kpaige]

Unfortunately the everlast is outside of my price range

 

[Kpaige]

So I have been to 3 diffrent LWS stores. I gotta say NOT impressed with the customer service, nor the knowledge. I knew more about their tig welders then they seamed to know and they pretty much could not answer my questions. They neededrxact specs etc then they could look up what to use etc. well I can do that I want experienced knowledge. You know the guy that has tried the diffrent setups and tungstens and what wirks for them type like you guys are providing.
It is also unimpressive that if you are only looking at the small machine they loose interest hand you a flier and say here you go.

 

[kkroger]

Generally a reason why they work in the store for minimum wage and not as a weldor... They only know what they know. some of the outside sales staff at those places are very knowledgable, because they go to their customer not the other way around.

Tire Kickers are hard to deal with too. We won't steer you wrong or try and up sell you because we don't get paid too!

 

[Kpaige]

I get sll that and I have been in construction and customer service for 28 yrs. But helping a guy at the bottom leads to bigger sales. I have walked away from lumber yards for the same reasons because they felt I was not a big fish then 6 months later they are knocking on my desk wanting to bid on the 130,000 dollar lumber project. Those people dont get my business.

 

[PT Doc]

No love for the HTP tig?

 

[kkroger]

No love for the HTP tig?

Untrue, AWESOME machine made by STEL in Italy, feature for feature a GREAT DEAL, BUT hardly a budget machine. But it certainly is a bad *** box.
When my yellow TIGs die I will replace them with HTP InverTIG 221s...
Heck if finances allow I will probably Supplement them with InverTIGs...

Features, lots of flexibility
Ck Torch and leads
SSC Pedal
Standard Connections
Yup Right up there with the Other RED and Blue and even the $$ Yellow.

 

[Kpaige]

Lots of love just out of my budget

 

[Kpaige]

If you had to pick 1 cup size, one filler rod, and one tungsten to do your aluminum welding 20 gauge to 1/4” what would you choose? Glass lense?

 

[kkroger]

20 Ga to 1/4 dang that is like opposites!
I'd run (depending on the joint presuming a LAP or Tee?)
the smallest cup I could probably a 4 or 5
I only use 3/32 tungsten so there is that... 2% Lanthanated
I'd run a gas lens but that is just me, heck probably a standard collet body would work as well in this instance... concentrate the Heat on the 1/4 that is going to SOAK it up, for filler rod I'd use something close to 20Ga probably 1/16 in this instance unless you want to buy a roll of MIG wire!
5356....

 

[NeuseRvrRat]

I'd get the AHP 200.

 

[Lelandwelds]

I would try to find some used Miller equipment. My first choice would be a Syncrowave 250 but a Dialarc HF or a 330 ABP would work.

Saying you can weld aluminum with DC is like saying you can drive nails with a ratchet. Pretty much any tungsten or cup will be OK in a pinch. Having the right stool, gloves, and foot pedal should be a bigger priority.

Finding a great local welding supply depends on where "local" is. You may have better luck with the independents. I found 80% of the walk ins weren't worth the effort. They would work me for advice and then buy from any place even $1 cheaper. If I could have perfectly ID the 20% worth the investment, I would have made the cut.

 

[Kpaige]

It will mostly be like thicknesses welded together I do have an immediate need to weld a cover plate 18 gauge to the flat 1/4” side of 2” bar to make a box of sorts

 

[Kpaige]

I have gotten info but basiccly looking now for what size collet, glass, etc to start with so once I have the welder I can start practicing and be somewhat close to what I need

 

[kkroger]

I would try to find some used Miller equipment. My first choice would be a Syncrowave 250 but a Dialarc HF or a 330 ABP would work.

Saying you can weld aluminum with DC is like saying you can drive nails with a ratchet. Pretty much any tungsten or cup will be OK in a pinch. Having the right stool, gloves, and foot pedal should be a bigger priority.

Finding a great local welding supply depends on where "local" is. You may have better luck with the independents. I found 80% of the walk ins weren't worth the effort. They would work me for advice and then buy from any place even $1 cheaper. If I could have perfectly ID the 20% worth the investment, I would have made the cut.

"Saying you can weld aluminum with DC is like saying you can drive nails with a ratchet."

Neither is incorrect, Heliarc (TIG) was originally done with Helium and DCEN, it will work and work fairly well and did for MANY years until the AC TIG came along... and you can drive nails perfectly adequately with a ratchet... But sure newer bettet tech is available, so just go straight to the nail gun....

 

[chillrich]

Kpaige
I have same requirements as you and although I'm in Canada much of what I have experienced over the past couple years will be of value to you.

I would have bought AHP but couldn't get one in Canada, I went with the Everlast. First the 185 microTIG and then PowerTIG 200 for the advanced functions. Canadian customer service is excellent, very good accessories/pedal. 200 has a slightly better arc.

There is a local tool store that has a good welding section, I will buy a lot of stuff there. LWS is not really geared toward dealing with the hobbyist so I avoid them for the most part.

I bought used bottles off of web classified locally and had them re-certified and filled by local tool store. I'm not positive that this is the best way but works for me.

I use 3/32 and 1/16 filler. ER70S2, 4043 and 308L purchased at local tool store.

Tungsten is 1/16 and 3/32 2% Lanthanated for everything. Purchased locally and from China on ebay. The tungsten from ebay does not perform as well or as consistently. I prefer to cut each tungsten and use a stubby back cap for access in tight spaces.

My preference is a air-cooled WP9 flexhead torch setup with gas lens(45V42) and collets from ebay out of China. Alumina #7 or #8 cups work well. Have tried the pyrex cups from LWS and China but they are finicky, easily broken and more expensive. The Furick are likely much better. I have used the wedge collets and they are excellent but cost prohibitive to get shipped to Canada.

Hopefully this helps

 

[Kpaige]

Chillrich
Thanks for the valuable input. Thats what I need
I did find that the 2017 everlast 185 is within my price range and seams like it has most functions a beginner would need

 

[kkroger]

Chillrich
Thanks for the valuable input. Thats what I need
I did find that the 2017 everlast 185 is within my price range and seams like it has most functions a beginner would need

185A won't be enough heat to join 1/4, 200 is better and probably cheaper for the AHP, I'm just saying. Looks like they are $719 now plus $30 instead of $680 + $30...
https://www.amazon.com/dp/B076BSD6PG/?tag=atomicindus08-20

Looks like they Jacked the NOVA pedal back up to $169 as well... Was $99 and "Fixed" at that price according to Oleg... Hmmmm....

 

[Kpaige]

I also found the ahp on weld.com with an actual flow meter upgraded flex head torch and consumables for 850

 

[kkroger]

It comes with a real flowmeter already the weld.com stuff is kinda old. since 2015 I think it has come with a better torch and a flowmeter. I have a pair of 2017s that both have them. I had a Dual Flowmeter for Purging before though.

 

[DetroitDIESEL444]

I have a Vulcan protig200. I have fired it up a few times. I’m no pro welder. The only thing I don’t like is it has a non adjustable post flow time. Quality seems pretty high though!


Sent from my iPhone using Tapatalk

 

[Kpaige]

It comes with a real flowmeter already the weld.com stuff is kinda old. since 2015 I think it has come with a better torch and a flowmeter. I have a pair of 2017s that both have them. I had a Dual Flowmeter for Purging before though.

Noticed that now

 

[Kpaige]

So what would one say if you are given the choice AHP tig 200x new $750 shipped
Or used miller diversion 180 $1150 shipped

 

[theoldwizard1]

TIG Welding Thick Aluminum using DC and Helium

Another video

Aluminum DC TIG Welding

 

[Crazyjake8493]

My vote is AHP AlphaTIG200x. I was in the same position, no help from the local shops and couldn't afford a comparable Lincoln/Miller. I've had my AHP almost 3 years with no issues. I'm a hobbyist and do small repairs for other people- steel, aluminum, and stainless. Never had a single issue with the AHP on AC TIG, DC TIG, or stick. I don't typically go above 1/8" aluminum so I can't comment on 1/4" performance.

Around $700 for the machine, stock torch and ground clamp are decent enough. The pedal is fine for a hobbyist, no need to upgrade to SSC unless you want to spend the money. I put a thinner spring ($4 gate hardware at Lowes) in my stock pedal for easier use, and I use it reverse of intended, with the fixed part under my heel, and toe on the pedal.

Not sure what a tank of argon will run you, shop around for the best price. I swapped an acetylene tank for an argon tank and only paid the fill.