Welding Tips and Tricks

I'm flattening the tungsen on the grinder when welding aluminum, but it's not "balling" when I weld. I assumed that the tungsten would kind of automatically ball up after a second of welding. Instead it get's a bit nasty looking and wondering if something's not right?

what kind of tungsten are you running? and also does it have a ac balance control?

Miller recommends Ceriated tungsten for the Diversion 165. The welder provides square wave AC 30% positive (for cleaning) and 70% negative (for penetration) at 120 Hz. I believe the 30/70 is the TIME ratio and that the amperage +/- is balanced but I could be wrong. That said, I have found it to be a real sweet spot for aluminum within the capability of the machine.

Ceriated tungsten is NOT supposed to ball. That is a phenomenon of pure tungsten used with sign wave AC from a transformer power source - old school. I was running some practice beads as recommended by Jody in a recent video (trying to use up the Argon in a leaking tank which I scored from craigslist - but that is another story). I was pushing my Diversion 165 rather hard with a 3/32" Ceriated electrode on which I had ground a slight flat tip. After making several beads I observed that the very tip of the electrode was very slightly rounded and quite shiny. Nothing like the "ball" on a pure tungsten electrode.

But there is better - 2% Lanthanated tungsten. Look back through Jody's recent videos. There is one where he did a test of various electrodes. I obtained some 2% Lanthanated electrodes from weldingcity.com. My D 165 is no match for a 3/32" 2% Lanthanated electrode. I don't think I could ball it, burn it or wear it out. I will not buy any other type of tungsten again. Try and find the video. It shows various electrode tip degradation. Very good information.

Ken