How To MIG Weld Aluminum

MIG welding, or metal inert gas welding, is a popular welding method used for a variety of metals, including aluminum. However, MIG welding aluminum can be more challenging than welding other metals due to its lower melting point and higher thermal conductivity. In this article, we'll take a look at how to MIG weld aluminum and some tips for success.

Materials You'll Need:

• MIG welder with aluminum spool gun or push-pull gun
• Argon gas
• Aluminum filler wire
• Welding gloves
• Welding helmet
• Protective clothing
• Aluminum cleaning solution
• Wire brush

Step 1: Prepare the Aluminum

Before you start welding, you'll need to prepare the aluminum by cleaning it thoroughly. Use an aluminum cleaning solution to remove any oil, grease, or dirt from the surface of the metal. Once the aluminum is clean, use a wire brush to remove any remaining debris and create a clean surface for welding.

Step 2: Set up the MIG Welder

Next, set up the MIG welder for aluminum welding. Aluminum requires a higher voltage and amperage than other metals, so make sure your welder is capable of welding aluminum and that you have the appropriate gun for the job. Use a spool gun or push-pull gun to feed the aluminum wire into the welder.

Step 3: Set the Gas Flow and Wire Speed

Once the welder is set up, adjust the gas flow and wire speed. Use argon gas as your shielding gas, and set the gas flow to around 20-30 cubic feet per hour (CFH). Adjust the wire speed to match the thickness of the aluminum and the size of the wire.

Step 4: Weld the Aluminum

Now it's time to start welding the aluminum. Position the gun perpendicular to the surface of the metal and start welding. Use a push-pull technique, pushing the gun forward as you weld to ensure that the wire is properly fed into the weld pool.

It's important to maintain a steady pace and a consistent distance between the gun and the metal. Too much heat can cause the metal to warp or melt, while too little heat can result in a weak weld. Keep the gun at a 10-15 degree angle and maintain a distance of around 1/8 to 1/4 inch between the gun and the metal.

Step 5: Finishing Touches

Once the welding is complete, use a wire brush to clean any excess flux or slag from the weld. You can also use a sanding disc or grinding wheel to smooth out the weld and create a clean, finished look.

Tips for Success:

Aluminum is more sensitive to heat than other metals, so be sure to use a higher amperage and voltage setting than you would for other metals.

Use a spool gun or push-pull gun to feed the aluminum wire into the welder. This will help prevent tangles and ensure that the wire is properly fed into the weld pool.

Keep the gun at a 10-15 degree angle and maintain a consistent distance between the gun and the metal to ensure a strong and consistent weld.

Use a push-pull technique to ensure that the wire is properly fed into the weld pool and to avoid tangles or jams in the wire.

Clean the aluminum thoroughly before welding to ensure a strong and clean weld.

In conclusion, MIG welding aluminum can be challenging but with the right equipment, technique, and preparation, it's possible to create strong and reliable welds. Remember to use appropriate safety gear, such as welding gloves and a helmet, and take the time to properly prepare the aluminum before welding. With practice and patience, you can master the art of MIG welding aluminum.