Welding Aluminum
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Elder User
Joined: Aug 2004
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From: Schwenksville,Pa
Welding Aluminum
I currently use a MIG welder with no gas. I just saw MIG wire for aluminum at Lowes. It's 0.30(solid I think) rather than my 0.35 flux core. Can I weld aluminum without gas? If so can I use the 0.30 wire in my gun?
Posting Guru
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From: Oregon
I was just looking for a similar topic and found this: https://www.ford-trucks.com/forums/s...luminumbrazing
Senior User
Joined: Nov 2003
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From: wallingford, ct
You need a spool gun to weld aluminum. If you put the aluminum wire in your mig, it will bird nest which means it will get all bunched up in the machine, not feed out due to the light weight of the aluminum.
Fleet Mechanic
Joined: Jul 2005
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From: Staten Island, NY
We use a Lincoln Mig-Pac 20 at work for that single purpose. We have hydraulic dock lifts at each position of our loading dock and they have aluminum diamond plate ramps on either end (dock to lift and lift into truck) They crack from abuse and overloading. They sell an aluminum conversion kit for the welder that consists of an inner sleeve for the umbilical and a properly sized feed wheel for the wire feed drive. The unit wasn't that expensive (couple of hundred, if I recall), so we leave it set up with 100% argon and aluminum wire. Otherwise it takes 30 minutes or so to convert back and forth from aluminum to either flux core or gas shield mig use. Works fine. Didn't cost much.
Postmaster
Joined: Apr 2000
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From: North of Tulsa, Oklahoma
Sounds like a lot of work to get the system ready to weld aluminum. What kind of projects do you want to weld? If they are not load bearing or structural support projects then you might want to take a look at some of the "Propane weldable aluminum rods." One of the brands I can think of is Allumalloy.(sp?)
Senior User
Joined: Nov 2003
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From: Iowa
I bought some aluminum welding rods from Bomgaars to use in my Miller stick welder. I welded up some snowmobile trailer slush guards/ramps. It's been 3 years since I built them and they are holding up great. It takes alot of practice but it cheaper then buying a new welder.
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From: wv
Originally Posted by 2003 6.0
I bought some aluminum welding rods from Bomgaars to use in my Miller stick welder. I welded up some snowmobile trailer slush guards/ramps. It's been 3 years since I built them and they are holding up great. It takes alot of practice but it cheaper then buying a new welder.
If you take a torch and heat the aluminum up to about 300-400deg. It will weld alot better!
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Barnbridge, Depending on what you are trying to weld, a mig w/ the aluminum conversion kit MAY work for you. I use a spool gun and have never had a problem. Greg
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Elder User
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From: Northern MD
Another alternative is to consider gas welding the aluminum. You'll need cobalt blue welding lenses, which make the puddle visible. Find a welding book, and it will explain the process and materials. If you're not welding a large volume of things, then this might be the way to go. It's not as easy as using a MIG welder, but it's another way to do it.
Posting Guru
Joined: Dec 2002
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From: Racine county, WI
Originally Posted by Scott S
You need a spool gun to weld aluminum. If you put the aluminum wire in your mig, it will bird nest which means it will get all bunched up in the machine, not feed out due to the light weight of the aluminum.
You will have to get some pure argon gas to weld aluminum, no gas = no weld. You may have to reverse your polarity to run the aluminum too. I'm guessing you have a small wire feed welder? Aluminum likes amps so don't expect to do anything too big. Get a MIG convertion kit if you don't already, hook up the argon and go for it.
Hotshot
Joined: Oct 2002
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From: The Big, Oregon
Aluminum needs a/c to weld by any process. If your welder says it has a d/c output, then it's no good for aluminum.
I have stick welded aluminum before, it's real picky, though. The slightest breeze will cause the puddle area to blow out or burn through, depending on the thickness of material.
I have stick welded aluminum before, it's real picky, though. The slightest breeze will cause the puddle area to blow out or burn through, depending on the thickness of material.
Hotshot
Joined: Feb 2004
Posts: 11,697
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From: Marengo, Iowa
Aluminum can be tricky to weld no matter the process, as it is hard to tell when it is about to drop out, so practice is necessary to get the feel for it. Reading the welds is tougher too, due to the fact of no heat signature. You really need to know what you are looking at to know if it a good weld or not.
Senior User
Joined: Mar 2005
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From: Summit, MS
Aluminum does not have to have to be welded with AC only. That is true for TIG but not so for wire feed operations. Many larger welders and wire feeders are DC only. My MM 251 with a spool gun works great on aluminum. The only way to get it to push aluminum thru that whip on my rig is to lie about it. Like the others have said, AL can be tricky for a beginner so don't try to skimp on the equipment.
Postmaster
Joined: Apr 2004
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From: Bossier City, LA
Aluminum is AC only for TIG as rusty has pointed out. No wirefeed machines are AC, they are all DC. (240 input voltage and up) The difference it the process. Constant current vs. constant voltage, or constant potential voltage. CC is stick or tig welding. CV or CP is mig welding. Using CV or CP is all DC. Using CC can be AC or DC. Or a much simpler answer is DC if welding aluminum with a mig, AC if welding aluminum with a tig.
Ryan
Ryan
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Joined: Feb 2004
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From: Orange County, So. Calif
Spool gun info wanted.
I recently picked up a spool gun for my Miller 200. Also got a argon bottle. What settings should I start out with for welding some thin, (.060 - .090) alum diamond plate?
For ferrus metals I'm usually at 15lbs CO2-Argon inside and about 20 -22 lbs outside with heat & wire feed appropriate for material at hand.
I've no hint as to alum, so am waiting for your suggestions...
hotrod/Paul
PS: I've had the pleasure of watching several alum body builders weld up race car bodies, fuel tanks, etc. using gas torches. Yep, they all did use the blue glasses, picked up scraps from the floor for rod, and just were amazing. Tom Hanna, Kenny Ellis, Dave Tuttle, and Mr Bob Hansen were the culprets, and or I was their victum...
For ferrus metals I'm usually at 15lbs CO2-Argon inside and about 20 -22 lbs outside with heat & wire feed appropriate for material at hand.
I've no hint as to alum, so am waiting for your suggestions...
hotrod/Paul
PS: I've had the pleasure of watching several alum body builders weld up race car bodies, fuel tanks, etc. using gas torches. Yep, they all did use the blue glasses, picked up scraps from the floor for rod, and just were amazing. Tom Hanna, Kenny Ellis, Dave Tuttle, and Mr Bob Hansen were the culprets, and or I was their victum...