I recently started using a new machine and ever since i've had a problem with tugstens splitting.
Machine is a miller aerowave and i am welding mainly aluminum.
machine setup as follows:
A+ 200A
A- 240A
f- 120Hz
Bal - 85
Preflow - 2s
Post flow -10s
Machine set to AC
Zirconiated tungsten
Foot contactor and amp controll
Does anyone know what the cause of the splitting is? It also forms numerous small balls rather then one ball shaped end. (almost like a rock drill)
http://i261.photobucket.com/albums/ii62/zoeper/IMG00080-20110316-1108.jpg
Any suggestions welcome.
P

Are you sure your using zirconiated (brown band) electrodes? The problem you are having is usually associated with thoriated (red band) electrodes. The only cause that I can imagine would be contamination during grinding. These tungstens normally ball up nicely at the tip.

The electrodes i use are WZ8 white band zirconiated and i have been using them for years on my old machine (Hobart Cybertig) without any problems.
The electrode balls up nicely when i form it using DC electrode +, but the tip degenetates into that ugly globulous mass again after using it for a while on AC.
Grinding procedures have not changed in years, so i think we can rule that out as well.

My gut feeling is pointing towards wave form.

That is strange. unless you have opened a frsh package that is somehow flawed, the problem does point towards the welder. Have you always formed the ball on the tip using DC+? I have never heard of anybody doing that with a zirconiated tungsten. Although I use them at times, I prefer lanthanated, as they are excellent for s/s welding and don't tend to spit when welding with AC high freq.

I think it must have something to do with the balance between A+ and A-.
If someone is using one of these on Ali, I would like to hear what settings they are using and if they are having similar problems.
P

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