URGENT!--welding machine settings

[Kiev Fernandes]

My company is recently gone into aluminium boatbuilding and have recently purchased Panasonic MIG model yd-400... welding machines. I need help with the machine settings can ne one help me.....

[gonzo]

You need to train your welders first. They should understand how to set the equipment and adjust it to varying conditions. Send them to school.

[TeddyDiver]

http://www.directindustry.com/prod/panasonic-industrial-robot-welding/fully-digital-co2-mag-welder-29315-116051.html
To me it looks like a DC MAG (optimized for steel with CO2).. For Al you need AC MIG me thinks..

[Fanie]

You need to train your welders first.
Gonzo, Kiev - something wrong with this picture !
Welding Alu is not something you just sit and do, if your 'welders' doesn't know how to weld Alu they better go for a course !
I really hope they're not going to start welding Alu boats.

A capable welder will know how to set a mig welder... !

Welding Alu properly is an art. The guy who taught me is probably he best welder in SA... and I still cannot decently weld alu.

[gonzo]

That's exactly my point. There isn't a static setting.

[welder/fitter]

Kiev,
Contact the manufacturer & ask for technical support. They can connect you with someone who is familiar with it. I haven't used the unit, though I've seen a similar robot system. Your tech support can answer anything not covered by your manual. Are you using a tri-mix?

[Kiev Fernandes]

The problem is there isnt a school to train these guys in this state maybe elsewhere i dont know but we may be getting an expert to train these guys lets see wat happens. most of these guys have worked with MIG machines for MS work.

its 100% Argon

[TeddyDiver]

its 100% Argon
But is it AC?? I know there are some DC welding machines claimed to do ally but never seen/told how well, and reckon they are just for occasional use.. ?

[Johnnylee]

Great info here, thanks guys

[Fanie]

If you DC weld Alu it surface harden and you cannot weld there again as well as it will crack and break there. The AC makes the power flow back and forth and you control the hardness with the frequency balance. There really is a big difference between Tig amd Mig. Mig is very easy and fast.

If you could get someone to come over and play with your guys and their new welders it may help some. Alu weld is difficult, you do something wrong or you get poor results and you do not always realise what you do wrong. Someone to look over your shoulder and tell you watch this do that helps a lot.

What amazes me is the alu goes everywhere when I weld. My welder friend seems he doesn't even have to do anything, the stuff just comes together automatic evenly and fluently...

[tazmann]

Not much info on the YD-400, Is it for robotic or can it be used as regular mig? Is it pulse or pulse on pulse for aluminum? What thickness and grade aluminum you welding? What wire diameter and grade? It all makes a huge difference on any settings.

MIG/GMAW aluminum DC+ 100% argon

TIG/GTAW aluminum AC 100% argon with a few different mixes allso, can allso be done with DC+ with argon and I think heilium mix.
Tom

[Fanie]

This is my welder's handbook. I have no idea what your machine looks like, but maybe something in here can help you. There is a 'first try at Alu weld' you could look at.

I can't upload the figgin file :( I'll keep trying but the attachment window say I'm not connected. You can see obviously I am.

Finally...

[Kiev Fernandes]

The machine is a DC with base negative 100% argon. we havent used the pulse option but has an option we were trying for sometime butt welding at various settings but in vain. I got some settings frm a book boatbuilding with al and it worked stable arc spray welding no spatter clean weld. but while filet welding it made a hole in the plate so lets see tom wat new probs we have to face....

[Kiev Fernandes]

yeah thanks fanie i got it.

[tazmann]

Hey Kiev
Sounds like you have a good start with it, Just keep playin with it. If youre blowing holes, eather run a lot faster travel speed or turn it down a smidge or both.
Here is a pdf guide might help
Tom

[Kiev Fernandes]

is the black deposit arround the weld normal or there is a prob with the machine setting???????

Tazmann the guide u gave me very helpful i need to know the settings given in the pdf can they be used for pulse mode

[tazmann]

Kiev
Yes the black is normal, more so with 5356 wire. should wipe right off?
Pulse settings will be a little different you could use them as a starting point and adjust from there. I had to learn my lincoln invertec the same way "no charts to go by" What I did was start with lighter gage material and set the output in the lower range and adjusted the wire speed to that. you find out real quick if its to hot or cold. when you get it dialed in to what looks and runs good then start doing youre bend or tear test and dial in from there. If it has arc control just leave it in the middle setting to start with and when you have it dialed in welding good then play with it up or down and you can see the difference it makes. It just takes time and take notes as you go. You will find the each different joint configuration for a given material thickness the settings are different.
Tom