@ FitNPipe - consider an alternate approach. Silver (4-6%) Soldering. If you do elect to apply traditional TIG the fuse the assembly, def practice-learn-practice-learn- - prior to arclight on the actual keg. Common wall thicknesses for Sankey style SS kegs are 14 ~ 18 gauge. Fitup needs to exacting ...

@ WeldersWife - strongly endorse the Lincoln 201MP. The machine is dual-voltage (120v, 240v) and will allow you to MIG, DC TIG (all materials except magnesium/aluminum), and Stick weld. As a MIG unit, she is nice/nice.....with .030"/.035" wire .....and will adequately fuse 3/16" steel...

@ Greybeard - both PEEK (polyetheretherkeotone) and PTFE (polytetraflouroethylene) are used as thermoplastic-based isolators for TIG torches. In the two graphs below, PEEK is the upper bar while PTFE is the lower bar for a given Thermal Property or Mechanical Property. We've used both materials for ...

@ MinnesotaDave - that image is a solid descriptor. The origin of that figure is from a 1980 DOE Report authored by Key of EG&G, Anode/Cathode Geometry and Shielding Gas Interrelationships in GTAW . Note, the base material for all runs was 304SS. Regardless, the same principles ring true for oth...

@ olek - in TIG welding, the temperature in a plasma arc column varies from the tungsten (cathode) to the material (anode). The reported values in literature by arc physicists, institutions, and industry are all over the map, but 6,000 to 10,000 deg F is a generally accepted temperature range for th...

@ lexxman - recommend using max amperage (250A) with your machine for both 1/4in and 3/8in Ally work. GREEN Tungsten with balled end will work; BLUE Tungsten (with micro ball -or- blunt angle profile) is even better. Lanthanum in the matrix acts as an "emission-enhancing oxide" and improve...

@ TheBeardedWelder - we run a Dynasty 200DX with both Ar and H25 shielding, and colloborate with a local business who operates several Dynasty 700s. Personally used their rigs on 3/8” 6061-T6 with 1/8” BLUE Tungsten and staright Ar shielding. Don’t recall the amperage, but the joints were fillets. M...

You are most likely on the proper investigative path. What defect (hot/centerline cracking, cold/underbead/traverse cracking, etc) are you experiencing? What can you tell us about the geometry of the machined joint? Single bevel? J groove? U groove? Are you working from a WPS? PreHeat, IP Temps, and...

....but if his is newer then 2010, then it can be upgraded with all current software.... A Dynasty 200DX is not/not software upgradeable, irrespective of date of manufacture, unless Miller offers some hotrodded ‘new’ motherboards for these units. The “200s” do not have an I/O port to upgrade the in...

@ oldeshooter - we also run a Lincoln 210MP, mainly for MIG process with .030 wire with C25 shielding gas, and for training humans with DC TIG. Excellent machine. Recommendations: * Integrate a 12” x 24” x 1/4” Aluminum plate to your welding table for all Stainless Steel work. Connect work lead dire...

@ MinnesotaDave - fusion welding aluminum foil is about about easy as it comes. Amps aren’t key, fixturing/fitup is crucial. Now, if you fused the surfaces via “open root” you’re a king.

Ron C shows his craft on 1thou Ally,

https://youtu.be/0p9s3DxMZ0A

99% of the time, we run 1/8” Tungsten on ferrous and non-ferrous materials ranging in thickness from 24ga (.025”) to 1/4”+. BLUE Tungsten for all Ally work, and RED Tungsten for all other materials. Inverter machines. The key is end preparation, tip profiling, and operator proficiency. We also micro...

@ Mojo88 - what stainless grade was used in the photo shown? T409 is an inexpensive variant commonly used for SS exhausts. And many times 409SS is coated with Aluminum to aid in preventing corrosion. If your practice SS sections were Aluminzed 409, then the popping you experienced could have resulte...

@ m0mri - see sections 2.2.1 and 2.2.2 of the DGP Tungsten GuideBook to understand the homogeneity/distribution, and associated Work Function (eV), of the "rare earth oxides" embedded in alloyed Tungsten. Figure 1 illustrates the distribution concept.

"18/8" is one common grade of stainless steel used in cookware. 308 filler would be appropriate.

Recommend you first check out this Stainless Steel (INOX) - Cookware article to explore the potential grade of your stainless steel. Both 300 and 400 series SS are used in cookware.

@ Weldworks - we also run a Lincoln 210MP. Mainly for .030" solid wire MIG with 230v input power. Have not yet ran the rig in FCAW-G, as we use our Miller weapons (XMT 304 CC/CV; Trailblazer 301G w/ Extreme 12VS) with .045" Lincoln/ESAB wires for heavier duty applications requiring deep pe...

@ flylow188 - Lincoln Electric SquareWave 200 is an excellent rig for welding ferrous and and non-ferrous materials. Definetly adaptable for 4130 tubing sizes common to the homebuilt aircraft (.030" -.050") Context. Recently teamed with Lincoln Electric at EAA AirVenture 2017 (Oshkosh, WI)...

@ JoeyTheWelder56 - based on your experience as a PipeLiner, you'll def figure out how to tame the Aluminum puddle for TIG work. Requires time and proper tactics. Attached are a few shots showing some recent weld lines on .0453in thick 5052-H34 Aluminum. After properly cleaning the base metal (degre...

Torch manufacturer? Base metal thickness? Experience level in operating an O/F torch? We run Smith/Miller OxyAcet and OxyPro torches. Medium Duty rigs. In our OxyAcet rig with an MC12 tip in "00" for cutting 3/8" steel, we run 10psi for the fuel and 20psi for the O2. Yields a kerf wid...

@ Shastri11 - start by reviewing this tech sheet on Martensitic 410 Stainless . Your purported through-hardness value of 170 BHN is below the avg for 410SS, most likely owing to your reduced (from 0.15%) Carbon content of 0.12%. Typical avg values achieved for hardened/tempered 410SS are 200 BHN (38...

.... I have seen videos of guys doing similar welds on outside corners with the parts clamped to an aluminum block. So I tried this on some scraps with pretty OK results. They were overlapped and fusion welded..... Several ways to attack the OCJs (outside corner joints). Since your Aluminum is thin...

Gated Works. 820mm x 1000mm outdoor gate. Mitered 50mm square x 3.2mm wall 6061-T6 HSS. 7ea 20mm round intermediate supports are coated Aluminum and interference fit into the HSS members. Burn-in via Miller Dynasty 200DX and CK Worldwide 18-series torch with 1/8" GREEN Tungsten (micro-ball) and...

Isn't welding with propane bad? I know it's ok for heating and cutting. Do you go through much more oxygen? The OP stated that welding is not a requirement. Attempting to weld with Oxy-Pro is futile. You need Oxy-Acet to weld. A truly Neutral flame with Oxy-Pro is not achievable. An Oxy-Pro's sligh...

....I am not very interested in acetylene welding....I would like to get a decent American product.... Based on your requirement to not/not OFW, strongly encourage you to consider Oxygen-Propane . Oxy-Pro is ideal in your situation, as you need the rig to preheat, cut, and shape. Oxy-Pro is less ex...

@ Goldhawg - your welds look clean with minimal carbide precip in the root side of your OCJ. Rest the root faces of your joint sections on Copper or Aluminum chill blocks. The large differential in the heat of thermal coductivity between SS and Cu/Al helps tame the process. Have a recomendation for ...