welding cast aluminum

[jwilly2]

I have some experience welding with a stick welder and a small Lincoln mig welder. I have never welded aluminum. In talking with some of my buddies who have some experience welding aluminum, I've been told that I probably need a 200 amp mig in order to weld the cast aluminum. Seems I get a different opinion from most everyone I talk to. Anyway, the aluminum I want to be able to weld is the cast type that farm pedal tractors are made of....most is not over 3/16 to 1/4 inch. I am considering either a Miller 210 or a hobart 210 Ironman. Is it possible to change the rollers to accomodate the aluminum wire or will I have to have a spoolgun? If it is possible to change the rollers, would I get the same results as from a spoolgun (as far as quality of weld)? Any suggestions as to which welder would be best? Which spool gun should I have? I will not be doing that much aluminum, so I don't want to spend any more than is necessary, but I do want a machine that is cabable of doing a nice job....strength of weld will be very important.

Thanks,
James

[Mike Sherman]

James, have you considered GTAW for this type of work? If that is not what you want, a MM mig with a spool gun is a very good way to go. I have seen many people use the regular mig gun for aluminum, I however am not a big fan of this. You will have far superior welds and far less problems with the spool gun.

[jwilly2]

Mike, Thanks for the reply.
As I stated, I have very little welding experience. I have no idea what GTAW is. I am wanting to weld the type of cast aluminum that pedal tractors are made from. If you are not familar with them, the metal is probably only about 3/16. The weld would need to look good and also, it would need to be strong. Maybe you wouldn't mind telling me what I need for the job. Of course I want to spend as little as possible, but at the same time I want to get a machine that will do exactly what I need.
Thanks, James

[Mike Sherman]

Gas Tungsten Arc Welding (tig), will give you the best looking welds on these little tractors. It will also be the most expensive tool to buy for aluminum welding. A spool gun will work, and with a little practice you can do thin material with it.

[jwilly2]

Mike,

Thanks for all the information.....it will be a BIG help when choosing a machine for my job.

James