Welding Tips and Tricks

Hello all, I am working at a new job that is 95% stainless and 5% aluminum welding. Working with these super thin coupons is causing a lot of warp, distortion, and awful looking beads. I've been out of welding school for a year now, and as we all know, welding is a perishable skill. I've watched a lot of videos and I'm just not making progress at the rate I feel I should.

I make a lot of butt joint tube fusion welds, and gatling style tube systems that run internally. I would like any and all tips anyone has to help me up the quality of these products. I've tested all amps from 40-80, my travel speed is not very fast, and I think I'm running with way too big of a puddle.

Again, any and all insight is helpful! Thanks

What power source are you using?

On thin joints, pulse is your friend, solves many overheating, warping and colour finish problems.
Also chill bars, multiple tacking and clamping restraint are handy helpers.
Back stepping and skip welding are important considerations.

I’d be lower than 40 amps for 0.035 stainless. Like closer to 22-24 amps. I sure hope you’re running enough gas coverage and a back purge? That will help a LOT. Maybe you can post up some pictures?

Also, material that thin welds better with a smaller diameter tungsten. Use a 1/16”, Red, needle point sharp! A #8 or #12 cup, 18-25cfh.

All good answers, but a photo or 2 would be a big help.

Are you welding to any code, or specific weld symbols on the print?

As welded or surface finish requirements?