How to MIG Weld Aluminium
MIG or metal inert gas welding is a type of gas metal arc welding. It is used primarily to create seems and connect metals using electrodes and shielding gasses heat and affix metal wiring. Though it was originally developed for softer metals such as aluminum, most MIG welders today are used for steel, and their hot temperatures are too great for soft metals. Consequently, MIG welding aluminum requires special equipment and attention to the delicate process of handling the welder, the wire and the surface.
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Things You'll Need
- MIG Welder
- Control unit
- Aluminum wire spool
- Degreasing solvent
- Stainless steel wire brush
- Aluminum feeding kit
- 4043 aluminum alloy filler metal electrode or a 5356 aluminum alloy electrode
- Argon shielding gas
- Insulated gloves
- Face shield
Instructions
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1
Select the appropriate MIG welding machine for the job. A 115 volt feeder is good for 22 to 12 gauge aluminum wire. A 230 volt machine can handle 22 gauge up to 3/16 of an inch, or even up to 1/4 of an inch with ample preheating time.
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2
Choose the best control unit for your budget. A continuous voltage control unit allows you to fine tune the voltage anywhere within the range of the machine and is more expensive. A tapped control is cheaper but is limited to four or five pre-selected voltage settings.
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3
Limit your welding choices to flat, horizontal welding patterns. In addition to limiting the problems associated with aluminum welding, this will also allow you to focus on non-critical welds that could result in serious damage or injury if they fail.
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4
Load the wire by holding the spool tightly so it doesn't unravel with one hand, and then locking the wire into place in the drive roll with the other hand.
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Set the drive roll tension by holding the nozzle about one inch away from an insulated surface and setting the tension to its lowest position. This will allow the wire to slip slightly. Tighten the tension setting gradually until the wire stops slipping.
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6
Clean and dry the surface on which you are welding with a degreasing solvent and a clean stainless steel wire brush. This will remove debris and oxides from the welding surface.
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7
Keep the gun straight as you are welding to avoid creating kinks in the wiring that will cause the aluminum wire to feed poorly.
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Tips & Warnings
Use an aluminum feeding kit.
Use a 4043 aluminum alloy filler metal electrode or a 5356 aluminum alloy electrode.
Use one hundred percent argon shielding gas.
Do not allow the spool to uncoil while loading the wire.
Wear insulated gloves and a face shield while welding.
References
- Photo Credit mig welder image by Jake Hellbach from Fotolia.com
