The thing about Aluminum that makes it more challenging to weld is the thermal conductivity.
The piece welded in the video above required 200-225 amps.
If that piece was twice and the same exact thickness, it would probably have required another 10-20% more amperage due to the conductivity.
Thats where a low preheat of 150-200F can help a lot.
Preheating aluminum slows the cooling rate, drives off moisture, and lessens the amperage required.
WELD PROCESS = TIG, GTAW, GAS TUNGSTEN ARC WELDING
METAL TYPE = ALUMINUM 6061
THICKNESS = 1/4”
WELD TYPE = FILLET WELD
JOINT TYPE = LAP
POSITION = 2F HORIZONTAL
AMPERAGE = 225 AMPS CONTROLLED WITH FOOT PEDAL
TUNGSTEN = 2% LANTHANATED, 1/8"
FILLER WIRE = 1/8” 4043
POLARITY = AC
GAS FLOW = 18CFH
CUP SIZE = 7
ADDITIONAL SETTINGS = AC BALANCE 30% CLEANING, AC FREQ 77HZ
PRE FLOW = 1 SEC
POST FLOW = 10 SEC
TIPS: KEEP A FAIRLY TIGHT ARC AND KEEP TORCH ANGLE TO A MINIMUM
Aim for an arc length that is equal or less than the diameter of your tungsten electrode.Torch angle can be forgiving provided your arc length is tight.