Well I have gotten Pretty handy at using the mig welder for steel and sheetmetal.


I bought some aluminum weld wire for it.... now what else do I need to weld aluminum?


As the manual dosen't even mention aluminum in there..


Thanks,

Greg

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Argon instead of CO2. Which is a different tank and regulator.

Different tip size (the wire of course)

And I think the polarity is different, but I'm not sure.

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Ed
64 Valiant 225 / 904 / 42:1 manual steering / 9" drum brakes

What kind of aluminum are you welding?

If it's processed aluminum like plate/sheetmetal, then Tig is the way to go to keep it from warping too badly...

On TIG we always used reverse polarity to weld (don't grab your project while connected... it doesn't feel good!)

If you intend on welding on a casting like an intake manifold or a set of feather duster bumber reinforcements, you may have to find another alternative than MIG to get it to take (this kind usually has a hard time taking penetrations into the base metal and will reward you with two outcomes... popping and snapping and blowing the weld out while doing the weld... or it'll look good, then become brittle and just 'fall out' of the weld when you thought it was good enough...)

I'm lucky to have a father-in-law that's been doing that kind of thing for 40+ years and it takes some experience to get it right... maybe try to find a similar material in the junkyard (an old 5.2 magnum intake...) and clean it up and try to weld on that just to see where things stand...

Best of Luck, this isn't the easy part of the project...

-D.Idiot

cast aluminum is very difficult to weld even with tig regular aluminum isnt so bad as long as its clean. With dirty aluminum you get alot of proprosity and it doesn't weld right most of the time ive used chemicals that clean the aluminum with sucess. Mig has to be set up just right for welding aluminum ive had alot of problems with the wire crimping up inside the lines id go tig if i was to weld any aluminum and also because im certified for that process and yes need straight argon for this process it seemed very messy to me when i did it in school. It takes alot of trial and error to set up a mig welder for aluminum properly
Dave

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87 d150 2bbl carb 225
79 f250 300 v8
97 cavalier z24
83 f150 straight 6
89 f450 diseal 4x4 dually 5sp

Ok Thanks All --- Yes I know if I wanted to weld all-out full bore aluminum stuff I would be getting a tig machine - but for now it's nice To try and get the most outa what I have


Thanks, Greg

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Which MIG welder do you have?

There are kits for different manufacturer's machines to replace the inner flex so you can run Aluminum through the feed cable. Also, the spool guns that are available make things easier.

If your using Aluminum wire through your feed roller, you will have to be very careful about the tension. Different feed systems produce different results. In the case of Aluminum in MIG welders, they tend to be finicky.

The spool gun is the best way to do it, less trouble with miss-feeds in the machine, but they are heavy and clumsy. You can't get them into small places.

Best bet? Don't screw around with a MIG welder on Aluminum. Go TIG.

As soon as I have enough money....

I've got my big Marquette Stick welder, a Lincoln PM 180C, and took delivery of my dad's O/A setup yesterday. I'll have to rebuild the regulators. He bought Victor's top of the line back when he was going to Spartan School of Aeronautics. That was after he got out of the Army in '52. This stuff is amazing compared to the crap I see in welding shops these days.

CJ

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Part of Tyrde-Browne Racing

ive got a miller trailblazer and i plan to get the mig and tig hook ups in the future when i have extra income i also a have a miller matic 250 mig

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87 d150 2bbl carb 225
79 f250 300 v8
97 cavalier z24
83 f150 straight 6
89 f450 diseal 4x4 dually 5sp

Sounds like nice stuff... Like that blue paint do Ya!

Let me rephrase that.

Greg, What make/model MIG do you have?

The spool guns work OK. Since your not ready to dive in for a TIG, that might just be the way to go. The spool gun will keep you from having the feed problems illdeca outlined.


CJ

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Part of Tyrde-Browne Racing

it's a lincoln Mig - I forget the number now - I will have to look up the parts for the inner feed tube..

Thanks,


Greg

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I have been looking for a spoolgun for my MIG off and on since I have had the machine. Not like I have a need to weld aluminum that often; but it would be nice to have the capability when those things do come up. They also make what's called a "push/pull" MIG gun; its closer to the size of a conventional MIG gun with a mini feeder built in. The feeder you already have built in pushes, while the one in the handle pulls at the same speed. We had them in school. Like I said though, I have not had much call for aluminum repair, so having a good friend whom i have known for years that is a welding teacher that has access to whatever welding process I could imagine, does help. ive attempted TIG exactly once and could not keep the tip out of the weld puddle. So I have my buddy do my alum. stuff. (He's bringing his kid's car by for me to work on the brakes for him later today so no, I don't get it done for "free", but close)

ive used one of those push pull guns there pretty handy there also kinda heavy though

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87 d150 2bbl carb 225
79 f250 300 v8
97 cavalier z24
83 f150 straight 6
89 f450 diseal 4x4 dually 5sp

I have welded intercooler castings and plumbing and coolant castings with my little Century 120 volt mig. It is not the tool for the job but it can be done with some extra work.

The welder I have has a Tweco gun, so at least that part works well..

You need: 100% argon, the smooth liner (plastic, the one I got did not fit and I just ran it with the steel liner) a rubber feed roller, and the right aluminum wire. I also used those felt wire lubers that clip over the wire between the rollers and the liner. I do think I had to change the polarity as already pointed out, it's been awhile.

The mig cannot control the heat like it needs too. It will screw up about an inch of weld before it gets started.

What worked for me: Put a very good sized 45 degree bevel on both parts to be welded,pretty much all the way thru. Pre-heat the parts to about as hot as you can get them with a propane torch, this is the only thing that will actually make it work. Make sure you get it started on both sides of the weld. It will still start a little slow, then be in the groove and will then start to get too hot. You cannot really adjust this out on the fly, or move faster either. Just weld as far as you can and when it starts to get too hot (2"-3"), stop for a short cool off. Watch for the molten puddle getting just a little wider. It is a fine line between a good weld and a total blow out. Between stop and start points you will likely have to go back, grind out a pocket with a burr and close it with a small circular weld, like a rosebud weld.

I did not have any trouble with castings being too brittle, they were rather tough.

Find some practice material. Good luck, it can be done. You will begin to justify the price of a tig. Just doing my own intercooler mod saved me about $300.00 for one long evening of my time.