I could use some help setting up a Synrowave 250 to weld aluminum for practice. I have never done aluminum before and it shows.

The other day I set my machine up as below and had terrible results.
A/C
150A
Full Cleaning
3/32 tungsten 2% Lanthanated Blue
18 seconds post flow
Material was an old scrap aluminum dirt bike wheel I cut up, which I think is 6061
1/4" thick
Cleaned aluminum with SS brush, brushing one way to bright and shiny.
Cleaned with Acetone

Problem I'm encountering with puddle, no filler wire attempted, results were black with soot, uneven, rough, total mess, looks like a weld job from a caveman around the campfire.

Appreciate any feedback other than buying a new machine :)

I

Hmm.
First off, aluminum really likes filler metal. Even just puddling for practice beads needs filler.
Second, soot can come from lack of, or bad gas, as well as contamination on the base metal, filler wire, and/or electrode.
Third, for 1/4" aluminum i would want a good 250 amps available on the pedal. Don't have to use it all, but it helps to get going.

Correct me if im wrong here: The syncrowave's AC balance is a 1-10 dial right?
If its the one i'm thinking of '0' would be 55% EP and 45%EN. 😬
Try setting the Balance to '3' and let it simmer to see if it gets shiny.
Then try Balance of '10' and do the same.
Can you find any aluminum that is of known alloy?
That wheel my not be what you think it is...some aluminum alloys contain Zinc, Lead, and other nasties...If it stinks, STOP!
Make sure your gas flow is appropriate for the cup size.

Max cleaning may be toasting your electrode and giving you issues.

Long story short...Up the amps, Up the Balance, put on a respirator.... and call me in the morning.

Thank you so much for the advice, I’m going to get some proper 6061 today, I didn’t think much about it, until Brian mentioned if it stinks to stop, it smelled like burning rubber, it’s going in the trash bin.

I heard about this site yesterday on your podcast and signed up right away.

Super excited to watch the TIG video’s and keep learning.

Thank you Brian and Jody. Have a great weekend.