How to MIG Weld With Alumium
Metal inert gas (MIG) welding uses a consumable wire electrode and shielding gas which are continuously fed through a welding gun. Aluminum requires some specific changes for welders who are accustomed to welding steel. It's a much softer metal so the feed wire must be larger. Aluminum is also a better conductor of heat so welding aluminum requires more control over the power supply and the feed rate of the electrode.
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Instructions
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Select a more powerful welding machine to melt thicker electrodes. A 115 volt feeder can handle aluminum up to one eighth of an inch thick with preheating, and a 230-volt machine can weld aluminum that's up to one quarter of an inch thick.
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Choose the correct shielding gas. Aluminum requires a shielding gas of pure argon, whereas steel typically uses a blend of argon and CO2. This may require the replacement of regulators designed specifically for CO2.
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Use aluminum electrodes of the proper alloy and thickness. The electrodes for welding aluminum should be at least thirty-five thousandths of an inch in diameter. Thinner wire is more difficult to feed, and thicker wire requires more current to melt. A softer alloy such as 4043 aluminum requires less current, while a harder alloy like 5356 is easier to feed.
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Feed the electrodes more easily with an aluminum feeding kit. These kits are commercially available and include a non-metallic liner to reduce any friction on the feeding wire. They also have contact tips with larger holes to accommodate the expansion of the wire under heat.
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Keep the gun cable as straight as possible to keep the wire feeding properly. Softer wire is more prone to kinks due to feeding restrictions.
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