Hi there.
Ali Pulse GMAW...
I'm trying to interpret.
I tried fairly identical fillet welds on 6mm (1/4inch) extruded 6082
(Al-Mg-Si) at
230A and "+9" on trim (as hot as it will adjust) - reporting about 26V
215A and no trim (synergic recommended)
185A and no trim (synergic recommended)
and broke them.
The 230A weld was beautiful but broke easiest, seeming soft. The
tear-out was a good part of a millimetre (about 30 thou inch) into the
plate under the fillet.
No difference was obvious with the breaks of the fillets at 215A and
185A both no "trim". In blows to break or appearance of the very
shallow tear-out.
Anyone help to interpret this?
I was told to be careful of beautiful smooth Ali welds as they will be
seen to be the first to break when on a boat. Quite a cold looking
welds with ripples best, he said.

I never tried breaking spray-transfer welds in previous jobs, which
are smooth and run best (?) with simple constant progression but the
smooth judged-ideal condition was at a bit lower Amps and Volts and
the weld-pool was a very shallow "slanting finger-nail" on the front
of a rapidly progressing fillet bead. Able to comment about these?
Was on 10m/min (394ipm) and 23V as notes of day record (web search
suggests 220A at 10m/min wire feed speed)