I'm considering options for aluminum welding and I'm not sure what machine and setup would be best. I have an older Millermatic 110v for welding steel sheet metal. I've used solid 023 wire and CO2 gas with some great results for a hobbyist. I know this machine can accept a spool gun with an adapter. Maybe that is the best way to go or I should be looking to get another machine. Maybe a 220v arc welder for aluminum, tig or a 220v Millermatic with spool gun. I would like to stay with Miller and something used for a lower price point.
Advice for a machine to weld aluminum
- Thread starter wazzabie
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mike93lx
ALLIANCE MEMBER
Whether or not your current welder will work really depends on how thick you want to be able to weld.
Spoolguns get aluminum welding done fast, but Tig welds will be more precise and prettier. Which end of the spectrum do you want to favor?
Spoolguns get aluminum welding done fast, but Tig welds will be more precise and prettier. Which end of the spectrum do you want to favor?
Aluminum spool on a MIG machine is a great and easy way to weld aluminum, with pretty good results.
TIG is of course very precise and neat looking (and surprisingly not hard with some practice). AC settings, 100% Argon, proper filler rod. Do you have experience with TIG? It will take some practice to get it down as it requires a little ballet between your weld/puddle with the filler rod.
If you can find a used Miller 220 in good shape that's a nice machine to jump in with.
I'd like to hear if anyone out there has used the HF Vulcan or Titanium line specifically on AL, and if so what results have you had?
TIG is of course very precise and neat looking (and surprisingly not hard with some practice). AC settings, 100% Argon, proper filler rod. Do you have experience with TIG? It will take some practice to get it down as it requires a little ballet between your weld/puddle with the filler rod.
If you can find a used Miller 220 in good shape that's a nice machine to jump in with.
I'd like to hear if anyone out there has used the HF Vulcan or Titanium line specifically on AL, and if so what results have you had?
Have a HF Vulcan 201 I believe at work. My coworker welded up some aluminum square tubes with it. It was his first time. Actually turned out pretty well.
I weld a good amount as convenience. I have an aluminum dock, staircase and various other things. I tried and failed miserably to get good at it…so I pay people to do the big stuff. Whatever you buy, OP, try practicing first with a spool gun. It looks easy and is NOT. I can weld steel nicely, aluminum…nope.
there may be a JC or similar that has equipment you can try or rent to figure out how much machine you need. Good luck.
there may be a JC or similar that has equipment you can try or rent to figure out how much machine you need. Good luck.
Wamsutta
Well-known member
Get a machine that you can pair a water cooler with. Those big torches get tiresome after a while.
dnschmidt
Well-known member
It all depends on whether your welding beer cans or structural stuff. I've found TIG aluminum to be easier than TIG steel, but that could be on me, For anything 1/8" or thicker a spool gun or a pulsed MIG like the HTP Propulse set up for aluminum wire is the way to go. TIG is considered to be the ultimate skill in welding but that stated requires the most skill and the most practice. You need to do a lot of it to get any good at it if it's a once in a while job for you GET THE SPOOL GUN OR THE PROPULSE.
No. I'm a newbie. To start I would like to weld aluminum tubing and some brackets.
In a previous life I had access to a Miller Dynasty 210DX that I borrowed to do some aluminum welding. I had it maxed out to weld on some 3/8" aluminum (tig). It worked, but it was all the machine could do even with preheat. If the Miller didn't cost so much I'd by one myself.
gimpyrobb
Well-known member
Syncrowave 250with pulser, water cooler, and torch. I got mine for under $1k
Aluminum cylinder head use case would lean towards TIG. For the control mostly.
And a pretty powerful machine at that. $$$$$ probably.
Aluminum brackets might be done with MIG or TIG.
The material size and thickness dictate just how much amperage you will need in order to weld the pieces together.
Welding aluminum is not quite the same as welding steel. Mostly in some of the finer details. In general, aluminum welding is done 'hot' (higher amperage) and fast compared to steel.
A small 120V wire feed machine is limited on just how much output power (amperage and arc voltage) it can produce and would NOT be what I would want to use for welding aluminum.
Sheet metal thickness stuff would probably be the limits with that size/class machine, and if you don't practice and dial in the machine parameters and your skills and travel speed you can end up blowing holes through the thin aluminum pretty easily.
Define your workpiece thickness and that will help narrow down your potential needed machine power and process choices.
And a pretty powerful machine at that. $$$$$ probably.
Aluminum brackets might be done with MIG or TIG.
The material size and thickness dictate just how much amperage you will need in order to weld the pieces together.
Welding aluminum is not quite the same as welding steel. Mostly in some of the finer details. In general, aluminum welding is done 'hot' (higher amperage) and fast compared to steel.
A small 120V wire feed machine is limited on just how much output power (amperage and arc voltage) it can produce and would NOT be what I would want to use for welding aluminum.
Sheet metal thickness stuff would probably be the limits with that size/class machine, and if you don't practice and dial in the machine parameters and your skills and travel speed you can end up blowing holes through the thin aluminum pretty easily.
Define your workpiece thickness and that will help narrow down your potential needed machine power and process choices.
Aluminum in MIG or TIG is very sensitive to shielding gas envelope - in other words, something you really need to do in the dead calm of indoors. Believe me, to do it all with blue paint on the machine is going to cost big bux. Suggest you look at a Prime Weld or equivalent multi task machine and you then have full choice of process to use.
Farmall450
Well-known member
Ha, that's what I have - well a 250DX.
Came here to say the same. Prior to that I had a small Hobart EZ Tig - it worked for sure, but you were always in the pedal pretty much 100%.
I have a PrimeWeld 225, it’s been great. No issues at all, good machine.
primeweld.com
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theoldwizard1
Well-known member
This can be a problem ! Even a small breeze can disturb the gas from a spool gun or TIG torch giving you poor welds !
As stated, aluminum needs lots of power ! Forget 120V machines.
danski0224
Well-known member
I recently took a short welding class and tried out a Miller Multimatic 220 on aluminum.
Don't remember the exact thickness, but ~14 ga (0.064") seems about right.
I found it to be super easy to TIG clean welding coupons together, as did most others there with some TIG skills.
Definitely not the same as welding on "dirty" metal or odd positions.
Certainly took a lot of power to do it, though.
It was so easy to weld that everyone was cautioned to be aware of how hot the torch head became, and not to melt it. It didn't take too many 6" passes to get hot.
A water cooled torch head would be recommended based upon this experience.
And yes to any breeze being a problem.
APEowner
Well-known member
I was really happy with my Syncrowave but when it died recently I bought a HTP 221 and it's a better machine than the Miller ever was. A lot of that is the difference between a transformer machine and a modern inverter but some of it is the build quality. It's really good. I don't think you gain anything by paying for the blue paint.
That's based on just a couple hundred hours of operation so it's possible that it won't hold up for the long haul but, based on my impressions so far I wouldn't spend the extra for the blue paint.
That's based on just a couple hundred hours of operation so it's possible that it won't hold up for the long haul but, based on my impressions so far I wouldn't spend the extra for the blue paint.