Any experienced TIG alu-welders out there ?

[Seldom Seen Slim]

That's about the same as a sunburn, and don't forget that bad sunburns (well, really, any sunburn) can lead directly to skin cancers.  Be careful.

Nancy and I, living so far up that we don't do much outdoor sunning (or working, for that matter) have our own tanning bed at home.  We spend time in there year 'round, but especially before we head to the races.  We know very well that we're likely to get a big dose of sunlight -- and if we did that without having a tan started we'd be burned to a crisp within a few days.

[Gwillard]

That's about the same as a sunburn, and don't forget that bad sunburns (well, really, any sunburn) can lead directly to skin cancers.  Be careful.

Nancy and I, living so far up that we don't do much outdoor sunning (or working, for that matter) have our own tanning bed at home.  We spend time in there year 'round, but especially before we head to the races.  We know very well that we're likely to get a big dose of sunlight -- and if we did that without having a tan started we'd be burned to a crisp within a few days.

I received a 2nd degree burn on my knee one day when i was sitting at a bench Tig welding for about 6 hours. I had a small tear in my pant leg and didn't pay it any attention. A tear about 2 inches long led to a blister about 2 inches in diameter that took forever to heal.

[octane]

 










 

[Gwillard]

The welding is looking good.  

The chest burn, not so good.  

Hint: The welding magnet in you pic works great for holding parts in position, but it can really mess with a DC arc that gets close to it.

[octane]

The welding is looking good.  

Thanks. Kind of surprised myself there...ha ha

The chest burn, not so good.  

Hint: The welding magnet in you pic works great for holding parts in position, but it can really mess with a DC arc that gets close to it.

Ooops. What exactly could happen here ?


Don't wonna do any (more) stupid things




Any other safety issues I should know about ?
..typical stupid thing to do resulting in an electric shock ?
..what about the fumes ? How do you protect yourself

Thanks

[Gwillard]

Not really a safety issue with the magnet, just that if you get a DC arc real close (like within 1/2" or so) it will bend the arc a bit toward or away from the magnet depending on which magnetic pole is towrd the arc. Try it sometime just for fun with a piece of scrap steel.
Electric shock is not a big problem. Just use normal precautions you would use around any electrical devices. Oh, and try to always wear dry gloves. I've been "waked up" a few times when I accidently touched the filler rod to the tungsten. Kinda like an electric fence shock.
Tig doesn't produce much in the way of hazardous fumes EXCEPT for when there are residual cleaners left on the material.  Read this thread: http://www.landracing.com/forum/index.php?topic=6424.0
If in doubt, rinse with acetone and dry completely before welding.

Where did you get the pic if me testing the outlet? 

[octane]

YaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaHuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuu!!!!

Made my first ever alu-welded part, that will actually serve a function on the bike

A combined air-inlet and "keep my knee from interfering the throttle-cable-wheel"-contraption.


Welded tube to flange (is that the term?)



...started at the 'under'-side as tube was right at the edge of the flange
so wanted to do this part first before everything heated up
 and I would risk melting the edge of the flange




..and welded the thingy to the flange



That weld isn't too pretty, buy that is solely because thingy is
a different sort of alu, namely a cast-aluminum of some sort, and also quite thinner than the flange.
VERY tricky.
Well, that's my explanation......and I'm sticking to it !
.-)


Came out pretty decent. Not good, not bad,
but darn ; I'm pleased .
No burning through the material. No black burns




Just need to sand and polish it up, make a gasket and stick it on the bike.
The air-filter is a mock-up. A size that fits the tube will be mounted





As the famous quote says:

"That's one small step for mankind, but one giant leap for this here man"

.

[Seldom Seen Slim]

Nice, nice work.  I betcha you'll remember that one piece for a long time. . .

[Gwillard]

Good job!

[Peter Jack]

I'm impressed. A little more time and you'll be happy with the appearance too. There are lots of weldors who wish their first attempts had looked that good. There's something about starting in the real world that can screw things up. Keep up the good work.

Pete

[WhizzbangK.C.]

Congratulations. Now the challenge is to NOT make a whole bunch of parts "just because you can" and run out of time to finish the really necessary things before it's time to ship the bike. Trust me, this can be a real challenge. 

What did you see when you cut your weldments apart?

[ironwigwam]

Lars you are the man.
   Rocky

[octane]

Thank you Slim, George, Pete, Whizz, Rocky !

You have no idea how pleasing it is for an old dog like me to learn new tricks

Congratulations. Now the challenge is to NOT make a whole bunch of parts "just because you can" and run out of time to finish the really necessary things before it's time to ship the bike. Trust me, this can be a real challenge.  

Trust me; I trust you

.-)

What did you see when you cut your weldments apart?

Haven't done it yet. Will do today or tomorrow
when I go out to that place mentioned above where they do the big alu construction
as they have a nice big saw set up to cut alu.



BTW: just for fun I put the welder on DC , turned down the peak current and
tried TIG welding regular metal.
Boy'oh'boy; was that  e  a  s  y  compared to the alu welding !
First attempt



I love that machine !!!

[Kato Engineering]

I have perused a few of the posts and did not see a response reply to this before....
Does your welding machine have on the A.C. setting a mannor to change the current frequency or cycles...
many of the more recient units have this feature and if you can position the setings to about 50 cycles, the unit will make a significant/noticable HUMM that also helps cleaning of the oxide and allows an easier puddle/crater controll...(aluminum)
a "normal" setting on a non adjustable power supply unit is 60 cycles input ( out of  the wall power) and it also puts out 60 cycles to your hand unit.

dunno what your wall power output is over where you are located, but in U.S.A. it is sixty cycles.

[octane]

I have perused a few of the posts and did not see a response reply to this before....
Does your welding machine have on the A.C. setting a mannor to change the current frequency or cycles...
many of the more recient units have this feature and if you can position the setings to about 50 cycles, the unit will make a significant/noticable HUMM that also helps cleaning of the oxide and allows an easier puddle/crater controll...(aluminum)
a "normal" setting on a non adjustable power supply unit is 60 cycles input ( out of  the wall power) and it also puts out 60 cycles to your hand unit.

dunno what your wall power output is over where you are located, but in U.S.A. it is sixty cycles.

Ahh; never thought that the frequency had any influence on the welding,
but the thing is that over here in Denmark we do run 50Hz / 220V  on all wall power outlets,
so I guess that takes care of what you mention above,
but thanks for pointing it out.



BTW got my Amp-pedal yesterday.
MMMMMmmmmmmmmmmmmmmmmmmmmm; something's wrong if I'm not mistaken ( and I could very well be )
as it apparently is set up to turn DOWN amp when I press the pedal.
I can work it, turning down amp when for example getting close an edge etc.
but it seams terribly counter-intuitive to me, to to press it DOWN to get LESS amp !!???

Looks like this



...the red knob regulates the MINIMUM AMP reached when pedal is pressed ALL the way down
and when I lift the foot away from the pedal it goes up to the machines max ( close to 200)


Nope; I haven't connected it wrong as there is only one way to do it.

Confused !