What setting should a MIG welder be on for aluminum?
When it comes to MIG welding aluminum, the proper settings on your welder are crucial for achieving high-quality, consistent results. The ideal settings will depend on factors like the thickness of the aluminum, the type of wire you're using, and the power output of your welder. In this article, we'll provide a detailed guide on how to set up your MIG welder for optimal aluminum welding.
Selecting the Right Wire and Gas
For MIG welding aluminum, you'll want to use an aluminum-specific wire, such as ER4043 or ER5356. These wires are designed to melt and flow smoothly on aluminum, creating strong, uniform welds. Additionally, you'll need to use a shielding gas that's suitable for aluminum, such as 100% argon or a blend of argon and helium. Avoid using CO2 or other gas mixes, as they can lead to porosity and poor weld quality on aluminum.
Setting the Voltage and Wire Feed Speed
The voltage and wire feed speed settings on your MIG welder are critical for aluminum welding. Generally, you'll want to use a lower voltage (16-20V) and a higher wire feed speed (300-450 inches per minute) compared to steel welding. This helps prevent the aluminum from overheating and burning through the material. The exact settings will depend on the thickness of the aluminum, with thinner materials requiring lower voltage and higher wire feed speed, and thicker materials needing higher voltage and lower wire feed speed.
Adjusting the Welding Technique
In addition to the welder settings, your welding technique can also impact the quality of your aluminum welds. Be sure to maintain a consistent travel speed, keep the gun angled slightly forward (10-15 degrees), and use a short, stickout distance (1/4 to 1/2 inch) to ensure proper weld penetration. Additionally, consider using a weaving technique, where you move the gun side-to-side in a slight pattern, to help control the weld pool and prevent burnthrough.
Tips for Successful Aluminum MIG Welding
- Clean the aluminum surfaces thoroughly before welding to remove any oxidation or contaminants.
- Use a stainless steel or brass wire brush to clean the weld area, and consider using a flux-cored aluminum wire for added cleaning action.
- Preheat the aluminum to around 200-300°F to improve weld quality and reduce the risk of cracking.
- Maintain a steady, consistent welding speed and avoid stopping and starting the weld, as this can lead to porosity and other defects.
- Consider using a spool gun or push-pull gun setup for better control and feed of the aluminum wire.
By following these guidelines and adjusting your MIG welder settings accordingly, you can achieve high-quality, consistent aluminum welds that meet your project requirements. Remember to always prioritize safety and proper personal protective equipment when welding aluminum or any other material.
What voltage and wire speed for MIG welding aluminum?
According to miller you should be at 350-400 ipm on wire speed, 21-22 volts and 110-130 on amps.
How to convert a MIG welder to weld aluminum?
The main task is to replace the liner for the torch. The stock liner is steel which is fine for its intended purpose, but it is too rough for aluminum wire. A PTFE liner is inexpensive and will work fine with the aluminum wire. If you want to do normal welding later, you'll need to put the original liner back in.
What is the best setting for welding aluminum MIG?
Usually, a voltage of around 21-24 is ideal. You'll also want to ensure your MIG gun is set to DCEP (Direct Current Electrode Positive) polarity for the proper process. Finally, welding aluminum is best done with the spray welding procedure.
Can I use my MIG welder for aluminum?
Material thickness: Most reputable MIG machines can be used to weld aluminium down to 3mm thickness. To successfully weld materials thinner than 3mm, it may be neccessary to use specialist MIG or TIG welders with pulse capability. (Note: to TIG weld aluminium, you will need an "AC/DC" machine such as the 201T).
How many amps does it take to MIG weld aluminum?
Typically, these machines have a maximum output between 100 and 125 amps and cost a little more. They usually weld aluminum up to about 1/8 inch thick nicely. You will need to buy a new bottle of 100 percent argon shielding gas. You can't weld aluminum using CO2 or argon-CO2 mixtures.
What is the best amps to weld aluminum?
What amperage range to use during TIG Welding Aluminum?
| Aluminum Thickness | Tungsten Diameter | Amperage for TIG Welding Aluminum |
|---|---|---|
| 0.010”- 0.035” | 0.040″ | 5- 25 |
| 0.035″- 1/8” | 1/6″ | 20-85 |
| 3/32″ – 1/4″ | 3/32″ | 50 – 180 |
| 3/16″ – 3/8″ | 1/8″ | 171- 250 |
Do you need to change polarity when welding aluminum?
When TIG welding aluminum, DCEP or Reverse Polarity can be used briefly at the start, but it's still generally not used. However, that doesn't mean it's never used in welding, just that it's not ideal for TIG welding.
What polarity to MIG weld aluminum?
All MIG welding, including on aluminum materials, requires electrode positive polarity, while flux- cored processes typically use electrode negative. If you are switching your wire feed welder between processes, make sure to switch your polarity. This is a common mistake that many beginning welders make.
