Aluminum Welding With a Small MIG

[Dallas]

Hey all!
A while back I asked about using a smal MIG welder for Aluminum welding.
The other day I was messing around with my new 115V 130A MIG welder, when a friend of mine came over and asked if I could fix his "across the bed" truck tool box.
I figured I'd give it a try, since I couldn't screw it up too much, (There was a 16"X16" hole in the bottom).

We dug out a piece of 1/8" diamond plate to use for a patch and I got the bottle of argon out along with a roll of .030 Esabe 4043 aluminum wire.
After figuring out how to hook up the regulator to the new welder, I started my experiment.

The first thing we did was clean the nasty old aluminum with vinegar and a stainless steel brush, until it was shiney. Next I looked for a good place to put the ground clamp... I eventually had to hook a 24" wood working clamp to the box and clamp the ground to that.

After a few false starts with some birdnesting on the rollers, I got the wire tension right. (Caution: 4043 wire is really really soft and will birdnest in a heartbeat).
I set the welder to it's next to the hioghest setting (about 105A) and turned the wire speed to No. 8 out of a possible 10.

As I contacted the wire to the work I could see immediatly that the wire was melting a lot faster than any I had ever used before, which meant that I had to move the gun quickly or risk burn back to the tip.

I actually surprised myself! as I tack welded the plate on, the welding went very well.

So, Since I'm not a professional welder, and at the best of times make some REALLY UGLY WELDS, I am pretty proud of my accomplishment.

Here are the specs:
Welder:    Clarke EN130 115V 135A 20% duty cycle MIG at 135 Amps.
Gun:        Tweeco
Tip:          .035 Tweeco
Wire:       Esab .030 4043 aluminum
Gas:        100% Argon

[Barn Owl]

Aluminum welding is not easy, nice job.

[Ace]

Dallas, when I get to T-Ville I would like it a lot if you would show me how you welded that aluminum with a regular Mig welder. I might be promted to return home and try it with mine!

That is if you don't mind!

The only way Ihavehad any luck at all welding aluminum is by using a mig gun and high frequency!

Ace... leaving on the 4th

[JackConrad]

I think I see a seminar here!  How bout it Dallas?  Jack

[Dallas]

OK,
As soon as the rain quits here, ( we've gotten more in the last 24 hours than during Ernesto), and the ground dries out so I don't electrocute myself, I'll see if I can reproduce those results.

It could be like the bumble bee... according t science, he cannot fly, but he does. If you tell him he can't fly, will he fall down?

I keep being told that it won't work, but, it did!

If I can reproduce those results, and make some decent beads on a flat piece of aluminum, I'll try showing everyone what I do to achieve it. After that your on your own!

I'm a lousy teacher, so I don't know about a seminar at the Timmonsville Rally, but I'll see what I can do.

Dallas


Ya'll come to the Timmonsville Get Together and watch Me make a Complete Fool Of Myself![/i][/b]

http://www.busconversionstuff.com/eventpage.htm

[FloridaCliff]

Dallas,

Are you running the spool of wire in the equipment or do you have a spool gun by the trigger?

Cliff

[Dallas]

Dallas,

Are you running the spool of wire in the equipment or do you have a spool gun by the trigger?

Cliff

Geez, Me afford a spool gun??? Cat would kick my behind up between my shoulderblades if I asked for that.

Nope, this is just the wire run on the internal roller.

[bobofthenorth]

We have done the same thing with ESAB 250s.  It takes a patient man and a steady hand.  Eventually we bought a spool gun.

[FloridaCliff]

Dallas,

I don't have one either. 

I am on the lookout for a good used one though. 

There someone out there just wishing they could sell that one in there garage 

Of course, at a considerablel loss 

I used a buddys on my mig and Wow.

Cliff