Aluminum Welding ?
Thread Starter
Melting Slicks
Joined: Mar 2004
Posts: 3,472
Likes: 18
From: Lake Ozark, MO
Aluminum Welding ?
I have a regular home welder that is gas capable (but I don't use it)....I bought a roll of aluminum wire to use for a project. Can I weld aluminum without using gas? Does the aluminum wire have a flux core like regular wire?
Drifting
Joined: Mar 2005
Posts: 1,806
Likes: 3
From: Burlington WI
Aluminum requires Argon
There isnt any "flux core" aluminum.
Typically welding aluminum requires argon shielding gas and that your welder have a high frequency unit built into it to alternate the polarity for cleaning effect while welding.
Here is a good link with a bunch more information:
WeldingWeb
Chris B
Typically welding aluminum requires argon shielding gas and that your welder have a high frequency unit built into it to alternate the polarity for cleaning effect while welding.
Here is a good link with a bunch more information:
WeldingWeb
Chris B
Race Director
Joined: Dec 1999
Posts: 16,945
Likes: 9
you also need a nylon linered torch/hose and use it for alu only. The reg. steel wound core will contaminate the filler wire and ruin the welds. Secondly since it's DC there's no cleaning and you need to thoroughly clean the alu before welding. Then there's a problem w/ alu wire and the push motor wheels, it tends to squash the wire and clog up the wheels...basically mig welding alu is a PITA and it can only be done properly w/ a high dollar pulsemig setup, some radiator manufacturers use it for the larger seams because of the speed advantage (I think C&R uses it)
Burning Brakes
Joined: Nov 2005
Posts: 1,143
Likes: 0
From: Leander Texas
Mig welding aluminum is very possible with the proper equipment. A spool gun is normally used for welding with aluminum. The reason for this is that aluminum is a softer metal than steel. Being that it is softer it will cause birdsnests 
in your machine if you try to push it through a standard mig torch. Also 100% argon is required for the best shielding. Different techniques (push other than pull) have to be used to prevent contamination of the weld puddle.
A good quality mig setup with the spool gun, can run around $2500.
My Snap On "Muscle Mig 140" with "Flex Tig" & spool gun cost me $4000.
DR. Jay
in your machine if you try to push it through a standard mig torch. Also 100% argon is required for the best shielding. Different techniques (push other than pull) have to be used to prevent contamination of the weld puddle.A good quality mig setup with the spool gun, can run around $2500.
My Snap On "Muscle Mig 140" with "Flex Tig" & spool gun cost me $4000.
DR. Jay
Melting Slicks
Joined: Dec 2005
Posts: 2,441
Likes: 0
Originally Posted by Hvymtlc5
I have a regular home welder that is gas capable (but I don't use it)....I bought a roll of aluminum wire to use for a project. Can I weld aluminum without using gas? Does the aluminum wire have a flux core like regular wire?
made and fixed a few things using this method including repairng the thermostat housing threads on an aluminum intake, filling a hole in a evaporator core, built some aluminum heat shields out of sheet stock, etc. You can get the rod at Harbor Freight or for some better stuff follow this link:http://www.aluminumrepair.com/more_info.htm
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