How to Set Up an Aluminum Welder

It is important to set up an aluminum welder correctly in order to produce quality welds.

Aluminum is generally the metal of choice for many projects due to its high strength, corrosion resistance and lightweight nature. Despite the desirable characteristics of aluminum, welding enthusiasts as well as skilled welders often shy away from welding aluminum due to the challenges associated with this type of metal. For instance, because aluminum has a low melting point, aluminum welds require the right temperature. Regardless of your experience level, however, correct welder setup is the first step to producing quality welds.

Things You'll Need

• Welder
• Aluminum wire spool
• Welding gloves
• Argon gas

Instructions

1. Plug in your welder to a power source and turn it on.

2. Locate the wire spool brake and choose a minimum tension setting.

3. Remove the pin or nut from the spindle and load the wire spool onto the spindle with the loose end toward the drive rolls. Don't release the loose end until the wire locks into the drive roll. Put the pin back in place to secure the wire spool.

4. Feed the wire carefully through the drive rolls. The wire spool should only turn when you feed the wire. If it turns on its own, adjust the brake tension to the next setting. The wire should feed smoothly through the drive rolls.

5. Hold the nozzle at a slight angle approximately 1 inch away from an electrically insulated surface, or a surface that is not grounded. A piece of cardboard or a wooden surface will work. Select the minimum setting on the drive roll tensioner. Put on a pair of welding gloves and press the trigger.

6. Look at the drive rolls. If they slip when the wire makes contact with the surface, tighten the tension. Press the trigger again. If the wire continues to slip, tighten the tension and continue testing the wire output until the slipping stops.

7. Set up your welder with 100 percent argon gas. Use the machine's gas hoses and regulators. You do not need any special equipment to weld with pure argon.

Tips & Warnings

• Consider an aluminum feeding kit. Although you can weld aluminum without the kit, it will make the welding process much easier. The kit normally includes a nonmetallic liner, U-shaped drive rolls, contact tips as well as inlet and outlet guides.

• For occasional aluminum projects, use a 115-volt or 230-volt MIG welder. For aluminum production, use a MIG welder with 200 amps output or greater.

• Maintain the gun cable tangle-free to reduce feeding issues on the aluminum wire. Bends or tangles on the gun cable can result in poor wire feeds.

• Be careful that the wire does not unravel before you lock it into place, or you may need to buy a new spool. If only a small section of the wire unravels, simply cut if off.

References

• Lincoln Electric: How to Successfully Weld Aluminum With a Compact Welder

Resources

• Trailer Body Builders: Aluminum Welding Not Difficult, Just Different