Sput Welder Help

[IAMaxxer]

I have purchased a sput welder and have done some practicing with it... But up to this point I'm dissapointed in the welds I get... Can any one give me some pointers in its use... Seems the welds are very unstable and any lateral movement will break them... Not sure they would last in the ano bath.... What gauge of wire should I be using? Thanks for any help...Ross

[sswee]

The size wire I use depends on the part. I use 8 gage, like Radio Shack carries, on the putters at about 75 joules. The small parts I use about 20 gage at around 26 joules. The length of wire I use to connect a part is usually 8 to 12 inches long. A good weld will be very hard if not impossible to pull straight off but do not take much side to side motion to break. I usually check the welds by holding the part and lightly shake the wire. When in the tank, under aggressive agitation, the parts will flutter all over but I haven't had one go AWOL yet. Hope this helps.
SS

[mcaswell]

I have also found that it is best to thoroughly wet the surface, so that the impact of the wire goes through a liquid drop. This improves the weld, reduces splutter and leaves a smaller scar.

[sage]

I've never used a sput welder, and I don't know what the instructions say about it either, but I do a lot of TIG welding and the biggest problem with welding aluminum is the ozide layer that forms on it and inhibits the welding process. The water drop I can uderstand becasue it would shield the aluminum from the air around before and during the weld process. I would add also that thoroughly cleaning the aluminum piece and the end of the wire if possible under water, and keeping them wet so no air can reach them up to the time you perform the weld might help as well. In TIG welding argon is used to shield the weld and the AC current cleans the weld area while the argon is present to stop air until the metal melts and/or the filler rod is addded.

Sage