Tag Archives: welding aluminum

Sizzle, Crackle, Pop: Welding Aluminum

Mark in Vermont asks:

I am running a Miller syncrowave 250 DX. Frequently welding cast aluminum, it pops and sizzles. I have always been looking for better cleaning techniques or a different tungsten to help get a stronger and prettier weld. There is always alot of black around the weld, and most times holes just “appear” in the weld. Any suggestions or tips to help?

That’s an interesting question — You can try a couple of things and see if it helps.

Gas Lens Collet Body1. Use a gas lens collet body – this will improve the shield gas coverage, and allow you to run higher amperage while lowering the electrode and front-end parts operating temperature.

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