I wonder if the 250 amp figure is for DC. You get considerable tip splitting, or nodules at high amperage on AC. Jody suggests intentional balling to prevent this. Yes, and on the Aerowave I used to use we would intentionally ball the end. The Miller documentation for this Dynasty recommends using ...

I don't understand about the 175 max amps. I assumed with a dynasty 350 you would be operating with a cooler, water cooled torch, foot pedal or maybe a slider on the torch handle. I can see that the material is polished, you said it was 1/4 in. thk, is it 3003 alloy? just curious because that alloy...

Thanks everyone for your input. Ok... I made a couple changes. I set the amps to 175, the A/C balance 65% EN, and the frequency to 100. Things that were the same as before - Waveform: advanced squarewave, Gas: Argon, Tungsten: 3/32" 2% ceriated tungsten. I only did a slight more cleaning on the...

Thanks everyone! I'm gonna try these suggestions and report back.

I am looking for advice with some difficulty I have when welding .25" thick aluminum diamond plate. The material was sheared. The welds are outside corner welds. The machine being used is a Dynasty 350. Obviously set to A/C, machine defaults for wave type, orange, 3/32" Tungsten, 140 amps....