Finally Tried To Weld Aluminum

[WelderBill]

I bought a new Hobart 190 with Spool-Gun last month. . Last weekend I finally tried to weld aluminum.

I'm not used to the settings on the welder yet, I've only used it a few times on steel, and I know aluminum is harder to learn to weld. I learned to weld on a stick welder back in the 80's and used to be a welder underground in the coalmines. . So I'm new to MIG welding & welding with gas.

I can't find any videos of anyone using a Hobart 190 with the Spool-Gun 100, So hopefully someone here can give me some advice on welding aluminum. . I spent 3 days trying to learn the settings to weld aluminum.

Here's what I was using and the settings on the welder.

1.) The aluminum I was welding was a piece of 1/8" scrap I had.

2.) I was using .030 Hobart wire.

3.) Argon was set on 20 to 25.

4.) Welder voltage was set on 1.. ( as low as it would go)

5.) Wire speed was set on 70.

If I turned the voltage up higher than 1, It would burn through the aluminum. . With it set on 1, If I turned the "wire speed" down lower than 70, It wouldn't even start a bead. (it would just start to ball up)

Here's some pictures.







OK, As you can tell from the (first weld), It looked cold. . As I moved on down, The welds started to look hotter. . I welded all 8 passes without stopping, and the aluminum heated up.

Also, I didn't know but I was dragging the weld, and was told to push.


More pictures.

Where I have the ''red arrows". . Welder was turned down as low as it would go on 1, and wire speed was on 60.

Where I circled the welds in red, I turned it up to 5 and wire speed on 80. You can see how it started to burn through with the high settings. . I have also tried the volt settings between 1 and 5.






More pictures.

This time I used a different piece of aluminum. . It was a piece of 1/8" diamond plate. . I pushed the weld this time, and I was able to turn the welder up without burning through, But its still not the welds that I want.

1.) 1/8" piece of diamond plate

2.) Volt settings. 4

3.) Wire speed. 70

4.)Argon. 20 to 25







I practiced 3 days in a row, and just about used a roll of 1lb. wire!

Any advice would be appreciated!

[urch55]

Bill,
First off I think you're doing great, trying to get a 'feel' for your machine.
I do not have the 190 Hobart so, I can't help out with settings. But, what I can suggest is practice on some heavier sheet like maybe 3/16th". Use good looking or new aluminum. Use a stainless brush and wipe it down with acetone and a clean rag because some aluminum has a coating that can effect you welds. If you think your getting a "cold start" warm "preheat" your aluminum you should only have to do this on your first weld because as you weld on the same piece your warming it up. You can use a propane torch for the preheat.. 4043 .023 or .030 is a good wire to use.. Keep all grinding wheels, brushes etc. for aluminum separated from the ones you use with steel because you don't want to contaminate the aluminum as you prepare it for welding..

[WelderBill]

Bill,
First off I think you're doing great, trying to get a 'feel' for your machine.

Thanks! . . This was the first time I've ever welded aluminum, and I was told that I did pretty good being my first time! . . I don't expect to be able to lay nice lookin' beads just starting out, and I know: Practice. practice and more practice!

Yes, I need to learn the settings on this welder. . I can't understand why I was burning through 1/8" aluminum. . The highest setting I went to was 5, and I was told that I should be near max with the 190 when welding aluminum.

I was welding the best with the welder set on 1.

I do not have the 190 Hobart so, I can't help out with settings. But, what I can suggest is practice on some heavier sheet like maybe 3/16th". Use good looking or new aluminum. Use a stainless brush and wipe it down with acetone and a clean rag because some aluminum has a coating that can effect you welds. If you think your getting a "cold start" warm "preheat" your aluminum you should only have to do this on your first weld because as you weld on the same piece your warming it up. You can use a propane torch for the preheat.. 4043 .023 or .030 is a good wire to use.. Keep all grinding wheels, brushes etc. for aluminum separated from the ones you use with steel because you don't want to contaminate the aluminum as you prepare it for welding.

Good advice!

I do need some heavier aluminum. . I bought a new stainless steel brush and used it on the aluminum before I started. . I don't have any acetone, But I'll buy some and wipe it down like you said!

Thanks for the reply! . . I'll post more pictures when I give it another try!

[colin56]

For welding the aluminum, there is need of heat sink. The reason while is the aluminum's tendency for conducting heat in a good way. As there is need of using a heat sink for clamping the aluminum which prevent metal from warping.

[billbong]

Hi all, I just did some aluminium welding with the Multiplaz plasma welder I have......this is the first real job on alluminium, apart from the few bits and pieces of ally scrap I practiced on when I first got the unit.

I'd post a few pics, but I might get blasted for advertising the Multiplaz........... the job was for a pump frame for my spa bath, and the material was 30mm X 30mm X 3mm aluminium angle, mitred at the corners with a piece of 4mm thick 100mm wide plate across the frame to mount the pump on.

The whole lot got mounted on a brick platform outside my bathroom window and pumps water to the spa bath inside the house.

I had to use Mig wire for filler, and I just cut 4 pieces 400mm long off of a spool of 1.2mm Mig ally wire and twisted the three pieces together with my cordless drill to form a thicker filler rod.

I used the usual method as for gas welding by heating the filler rod and dipping it into the powder flux to coat it, having given the ally angle stuff a bit of a brush over with my wire brush to shine it up a bit, although it was in a pretty newish condition being a left over from a job.

You really need a pin point heat source with ally, and the 'Plaz has a lot of heat but with a more diffused spread which means you have to be quick or you get a melt down.

I originally planned to make the pump base from steel angle and get it galvanised, but I wanted to give the 'Plaz a workout on ally and also have a rust free frame for years to come.

Nothing is impossible if you plan to do it.
Ian.

[3 weelin geezer]

I would like to see pics. That contraption seems waaaaay too good to be true where you just add water and some scotch..to the machine. Well, maybe some for me too. Still, I just don't see how this 'magic' works where it makes the alcohol super hot just by adding water. I am just waiting for Chuck Norris or that Oxy-clean man to put it on their infomercial channel in place of late nite P0rn.

[canoecruiser]

There are threads on this site and Millerwelds and WeldingWeb discussing the Multi-Plaz. Note that it seems to be spelled two ways on the boards....with a hyphen and without.