Sorry CFH, the torch is water (coolant) cooled.

Sure, this setup for 1/4 aluminum plate was run with DCEN with a gas lense, 3/32 2% thorated tungsten sharpened to a point. I like the gas lense for the even flow characteristics of the gas, minimal turbulence. Straight Helium was used at about 15-20psi Machine was set at about 180 amps as I like to...

Try a .040 thick tungsten with a .020 diameter filler rod. The pictures look as your tungsten is too large and you are welding too hot. Switching to the smaller size tungsten should get you in the ballpark to weld those rainbow dimes that you are looking for.

Oh, yes that was the initial one inch or so because I did not preheat the plate before I welded it. Good catch man, its nice when people know what they are looking at!

Yes, I am left handed. I picked the plate up and tried to turn it to show the best lighting scenario. Sometimes I will "pedal" the bead in by short bursts of increased amperage while adding the filler material to make the weld perfectly even from start to finish. I know it is unconventiona...

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That's just a figure of speech, I am glad I stumbled upon this site as there are all kinds of tips and tricks to learn in this trade. I will do my best to upload some pictures as soon as my company lets me get back to welding (what I was hired for). I had the luxury of working with some pretty sharp...

If I can remember, I will take some pictures of welds on a 1/4 t joint and upload them. If everything is correct, people cannot tell the difference between DC and AC aluminum. I will take a picture of the weld before I brush it off so you know that I am not bullshitting you

Sorry, I had to register to comment on this. Yes, aluminum can be welded with DC and pass whatever tests given all day long! The preferred method is AC because people do not know what they are doing when it comes to aluminum DC plain and simple. If you brush the material with a stainless brush, clea...