Aluminum welding for beginners?

[wkparker]

Looking for advice on equipment needed to get me started welding aluminium. I have a fair amount of experience welding steel, and own a small Lincoln MIG welder that suffices for my shop projects.

A couple of projects I have in mind now would be better if made using aluminium, but I see so much conflicting advice that I thought I'd ask the GJ experts where to start. I'm not building race cars or rocket ships, so just looking for a place to start.

Sorry if this has been asked.., a search didn't turn up what I'm looking for.

Thanks!

 

[sponfit]

Lincoln square wave 185 is a good home machine

 

[RedneckWelder]

A/C Tig or MIG Spoolgun are the two common ways of doing it, along with mega $$ push/pull mig units. Some people may have luck on the cheap with a short MIG gun lead and a Teflon liner but aluminum wire tends to bird nest when pushing up a normal mig lead.

 

[lis2323]

A/C Tig or MIG Spoolgun are the two common ways of doing it, along with mega $$ push/pull mig units. Some people may have luck on the cheap with a short MIG gun lead and a Teflon liner but aluminum wire tends to bird nest when pushing up a normal mig lead.

That about sums it up [emoji106]

 

[dnschmidt]

I have both an Ahp Alphatig 200 AC/DC tig and an HTP Propulse 200 mig which is the absolute bomb. The Propulse is one of the few machines that you can do aluminum all day long using a conventional 8 foot long MIG gun. Both work well for me.

 

[wkparker]

A/C Tig or MIG Spoolgun are the two common ways of doing it, along with mega $$ push/pull mig units. Some people may have luck on the cheap with a short MIG gun lead and a Teflon liner but aluminum wire tends to bird nest when pushing up a normal mig lead.

I understood about three of those words... Did I mention I know nothing about this other than how to use my little Lincoln MIG welder?

 

[wkparker]

Lincoln square wave 185 is a good home machine

Thanks. I see a TIG 200 on their site - is that similar?

It's about $1700... way more than I want to spend before I stop outsourcing aluminium work really commit to doing it myself.

 

[pbon]

There are some $600-$900 ac/dc tigs. Eastwood and others I cannot remember. They are made in China but get decent reviews.

 

[lis2323]

There are some $600-$900 ac/dc tigs. Eastwood and others I cannot remember. They are made in China but get decent reviews.

You won’t find any Made In USA welders if you are looking at new, anyways. [emoji3]

 

[Aaron_W]

What size work are you planning on? Spool gun on a MIG welder is better for larger jobs. TIG is better suited to smaller more precise work.

There is a big learning curve to TIG welding compared to MIG. If you have done any oxy / fuel welding there is some similarity.

 

[Aaron_W]

You won’t find any Made In USA welders if you are looking at new, anyways. [emoji3]

There are still some assembled in USA from Globally sourced parts (or some such verbiage).

 

[lis2323]

There are still some assembled in USA from Globally sourced parts (or some such verbiage).

Yes I realize that.

 

[fartymarty]

Looking for advice on equipment needed to get me started welding aluminium. I have a fair amount of experience welding steel, and own a small Lincoln MIG welder that suffices for my shop projects.

A couple of projects I have in mind now would be better if made using aluminium, but I see so much conflicting advice that I thought I'd ask the GJ experts where to start. I'm not building race cars or rocket ships, so just looking for a place to start.

Sorry if this has been asked.., a search didn't turn up what I'm looking for.

Thanks!

OK, to be clear, I know even less about welding than you do wkparker. But I'm trying to learn more my self. From my research and assuming you want to keep it on the cheap...here is what I think you need to do, get a MIG spool gun (google it) because aluminum wire won't go through your current setup with out binding up. Assuming you are using a gas blend currently you need to switch to 100% argon for your shielding gas. I also think you need to switch polarity on your welder. I say this all very authoritatively and yet without any real knowledge or experience to back it up because...

... a lot of times the people that really know about this stuff won't respond to a simple request for knowledge...but boy o boy will they come out to tell someone who acts like an expert just how wrong and stupid they (me) really are. Hopefully now they'll start posting up here with the info you need...but be prepared for a few "you need to buy a Miller this or a Hobart that" responses where they don't really give you the info you need and yet they are allowed to post as experts with their one line answers and just expect you to take their word for it with your money.
Best wishes, and I'll learn here with you while I selflessly take all the arrows.

 

[txvwnut]

If you want a tig unit get an AHP Alphatig 201. These are great welders for not a lot of cash and several of us on here have and are pleased with them. For some good online instructions look welding tips and tricks on YouTube and or the fabricator series. Both of these channels give great instructions.

 

[wkparker]

What size work are you planning on? Spool gun on a MIG welder is better for larger jobs. TIG is better suited to smaller more precise work.

There is a big learning curve to TIG welding compared to MIG. If you have done any oxy / fuel welding there is some similarity.

Nothing huge or super complicated - some pontoon boat railing projects, couple of small platforms for the dock, a kayak lift. Nothing life & limb critical. Sounds like MIG may be the better approach.

 

[wkparker]

OK, to be clear, I know even less about welding than you do wkparker. But I'm trying to learn more my self. From my research and assuming you want to keep it on the cheap...here is what I think you need to do, get a MIG spool gun (google it) because aluminum wire won't go through your current setup with out binding up. Assuming you are using a gas blend currently you need to switch to 100% argon for your shielding gas. I also think you need to switch polarity on your welder. I say this all very authoritatively and yet without any real knowledge or experience to back it up because...

... a lot of times the people that really know about this stuff won't respond to a simple request for knowledge...but boy o boy will they come out to tell someone who acts like an expert just how wrong and stupid they (me) really are. Hopefully now they'll start posting up here with the info you need...but be prepared for a few "you need to buy a Miller this or a Hobart that" responses where they don't really give you the info you need and yet they are allowed to post as experts with their one line answers and just expect you to take their word for it with your money.
Best wishes, and I'll learn here with you while I selflessly take all the arrows.

LOL! Great advice and I appreciate you sticking your neck out. Maybe we'll both learn something!

 

[wkparker]

If you want a tig unit get an AHP Alphatig 201. These are great welders for not a lot of cash and several of us on here have and are pleased with them. For some good online instructions look welding tips and tricks on YouTube and or the fabricator series. Both of these channels give great instructions.

Well, that's the thing... I don't know if I want a TIG unit because I don't have any idea what the pros & cons are of MIG vs. TIG for a rank beginner who has no idea what he's doing.

I've spent hours on YouTube watching videos, but haven't found a single one that says "oh, you're a beginner? start here!" Until I have some idea what I *should* buy, I'm JAFO.

 

[MoonRise]

More detailed answer later ...

Short answer:

Welding aluminum is most commonly done with either AC TIG (aka GTAW) or with MIG (aka GMAW).

Both use either 100% argon as the shielding gas or an argon - helium blend for 'thicker' stuff.

TIG is slower but can be more controlled (depending on the skills of the person).

MIG can be 'faster' but has less control of the welding parameters once you start the weld compared to TIG.

Tech question : what thickness range of aluminum are you planning of working with? Relates to that weld parameters control aspect, TIG with a foot pedal (or other amperage control device ) can usually adjust the welding amperage while welding.

And also to how much welding power you will need to weld the aluminum. Once you get past 'thin' aluminum, you need a good bit of welding power (amperage) to successfully weld aluminum because of how thermally conductive the aluminum is.

And be aware that not all aluminum is even weldable.

Your 'small Lincoln MIG' is a 120 V machine? If so, you will be VERY limited on how thick of a workpiece you can even have a chance of welding.

A small 240 V machine increases the thickness options a little bit.

A lot of the recent small MIG machines can use a spool gun for welding aluminum. It helps a lot compared to trying to push a long thin very flexible aluminum wire through 10 feet of torch hose, which is usually a situation where the aluminum wire easily tangles up coming off of the spool and forms a "bird's nest " tangle.

Later ...

 

[HMCFab9]

MIG welding on aluminum is usually more for production work building big stuff. (Trailers, etc)
TIG is usually used on thinner more precise applications.

Figure out exactly what you want to do before you spend $$$$

I (mistakenly) bought a miller252 because it was "spoolgun-ready".
I should have bought a TIG instead.

 

[wkparker]

MIG welding on aluminum is usually more for production work building big stuff. (Trailers, etc)
TIG is usually used on thinner more precise applications.

Figure out exactly what you want to do before you spend $$$$

I (mistakenly) bought a miller252 because it was "spoolgun-ready".
I should have bought a TIG instead.

Curious about why you feel a TIG would have been more appropriate. Is it because of the control or the size projects you are doing?

 

[dr_clyde]

I would highly recommend a TIG machine for someone looking to get into aluminum welding.

They are far more versatile for the thicknesses and shapes of aluminum you have described as things you want to weld.

It has a learning curve, and you will be more limited by your experience than the machine.

MIG aluminum is a whole nother animal, and takes a fair amount of skill and practice to use effectively on thinner metals. It is more unforgiving, and has a lot more moving parts to consider.

I personally find you would want a 200 amp machine as the minimum to do much beyond sheet metal.

Plan on being into it for 1k on the bottom end for the machine, and you're looking at another $500 or so in gas, wire, torch accessories, and all the neccessary stuff to weld.

I really recommend the Lincoln SW Tig 200 for a beginner, as it comes with everything you need except a gas cylinder and some filler rod for around $1500 on sale. It will be hard to get a nicer machine for less money.

There are cheaper machines, and if that's all you can afford, go for it but have the knowledge that they are built to a price point first, quality and function second. You WILL find the limits fairly quickly. But as a starting place, they are pretty affordable.

 

[WAITS]

Try some aluminum stick rods out

 

[lis2323]

Try some aluminum stick rods out

..and be discouraged from ever trying to weld again. [emoji23]

 

[Copymutt]

I suffered through my Lincoln building docks.100% argon. Even though that welder may come w/ feed wheels for aluminum you’ll end up w/ bird nest and wasted wire. Spool gun is the way to go.

 

[TexasT]

If you want a tig unit get an AHP Alphatig 201. These are great welders for not a lot of cash and several of us on here have and are pleased with them. For some good online instructions look welding tips and tricks on YouTube and or the fabricator series. Both of these channels give great instructions.

X2 on the AHP 201xd I bought ours so we could do aluminum. But you will have to learn tig to do it and it does take some dexterity, patience and lots of hood time practicing. Opened a lot of things I couldn't weld before, when we made due with a little wirefeed setup with some 75/25 and a buzz box for thick stuff.



You will need some tungstens, and other consumables, cylinder of 100% argon and some time to make you into a weldor.

 

[wkparker]

I would highly recommend a TIG machine for someone looking to get into aluminum welding.

They are far more versatile for the thicknesses and shapes of aluminum you have described as things you want to weld.

It has a learning curve, and you will be more limited by your experience than the machine.

MIG aluminum is a whole nother animal, and takes a fair amount of skill and practice to use effectively on thinner metals. It is more unforgiving, and has a lot more moving parts to consider.

I personally find you would want a 200 amp machine as the minimum to do much beyond sheet metal.

Plan on being into it for 1k on the bottom end for the machine, and you're looking at another $500 or so in gas, wire, torch accessories, and all the neccessary stuff to weld.

I really recommend the Lincoln SW Tig 200 for a beginner, as it comes with everything you need except a gas cylinder and some filler rod for around $1500 on sale. It will be hard to get a nicer machine for less money.

There are cheaper machines, and if that's all you can afford, go for it but have the knowledge that they are built to a price point first, quality and function second. You WILL find the limits fairly quickly. But as a starting place, they are pretty affordable.

Great advice - thanks for your time.

 

[wkparker]

I suffered through my Lincoln building docks.100% argon. Even though that welder may come w/ feed wheels for aluminum you’ll end up w/ bird nest and wasted wire. Spool gun is the way to go.

I'm hearing that pretty consistently - thanks.

 

[wkparker]

X2 on the AHP 201xd I bought ours so we could do aluminum. But you will have to learn tig to do it and it does take some dexterity, patience and lots of hood time practicing. Opened a lot of things I couldn't weld before, when we made due with a little wirefeed setup with some 75/25 and a buzz box for thick stuff.



You will need some tungstens, and other consumables, cylinder of 100% argon and some time to make you into a weldor.

Thanks. I *hopefully* have plenty of time to practice!

 

[wkparker]

More detailed answer later ...

Short answer:

Welding aluminum is most commonly done with either AC TIG (aka GTAW) or with MIG (aka GMAW).

Both use either 100% argon as the shielding gas or an argon - helium blend for 'thicker' stuff.

TIG is slower but can be more controlled (depending on the skills of the person).

MIG can be 'faster' but has less control of the welding parameters once you start the weld compared to TIG.

Tech question : what thickness range of aluminum are you planning of working with? Relates to that weld parameters control aspect, TIG with a foot pedal (or other amperage control device ) can usually adjust the welding amperage while welding.

And also to how much welding power you will need to weld the aluminum. Once you get past 'thin' aluminum, you need a good bit of welding power (amperage) to successfully weld aluminum because of how thermally conductive the aluminum is.

And be aware that not all aluminum is even weldable.

Your 'small Lincoln MIG' is a 120 V machine? If so, you will be VERY limited on how thick of a workpiece you can even have a chance of welding.

A small 240 V machine increases the thickness options a little bit.

A lot of the recent small MIG machines can use a spool gun for welding aluminum. It helps a lot compared to trying to push a long thin very flexible aluminum wire through 10 feet of torch hose, which is usually a situation where the aluminum wire easily tangles up coming off of the spool and forms a "bird's nest " tangle.

Later ...

Thanks for the great advice. I'll mostly stick to 20-18-16 gauge material, so it's sounding more and more like TIG is the way to get started.

 

[lis2323]

Thanks for the great advice. I'll mostly stick to 20-18-16 gauge material, so it's sounding more and more like TIG is the way to get started.

For that gauge material TIG would be your best choice. [emoji106]

 

[theoldwizard1]

And also to how much welding power you will need to weld the aluminum. Once you get past 'thin' aluminum, you need a good bit of welding power (amperage) to successfully weld aluminum because of how thermally conductive the aluminum is.

This !

If someone is going to be doing a LOT of aluminum welding, you it to yourself to checkout the HTP Pro Pulse series of MIG welders. Also check out the Zila YouTube channel.

These are expensive machines, but you can learn to weld Al very quickly and it lays down beads FAST !

Final notes on AL welding :
• All Al has been heat treated. Welding changes the heat treatment at least local so you will lose some strength in the material
• Al flexes a lot more than steel. Repeated flexing will cause the Al to crack, commonly at the weld (probably because of the previous comment)