Aluminum Boat Welding...Not That Hard!Aluminum Boat Welding or should I say Mig Welding was the process
we used to build this 65' hull. Gas Metal Arc Welding (GMAW), also known as MIG welding.
GMAW - Gas Metal Arc Welding - Mig Welding Gas Metal Arc Welding needs a Clean surface in order to have a strong weld. This process is verisatile weither welding from 3/16" to larger plate thickness. Argon Gas is used for welding aluminum, it has good penetration for strong welds.
Inert Shielding Gas - Argon gas was used for 1/4" - 1" plateArgon-Helium mixtures, 25-75% helium can be used for thicker plates, but...are more expensive. We used Argon Gas for all the welds including 1" plate for the bottom of the keel.
Shielding Gas is the protection you need to form a good weld
it keeps the oxygen from corrupting the weld as the fed filler metal and the base metal come in contact.
Key Tip: Pourus welds are caused by, not enough inert shielding gas pushes air away...oxidation, oil, grease, paint, moisture, dirt, early morning Florida dew. 
Key Tip: Clean the area your going to be welding right before welding. Use a hand grinder or metal file to clean the edges off and get rid of the burrs. The plate surface also...this way you have a smooth clean area to weld. With practice you can master the technique of mig welding.The spool gun needs to be moved along the joint at a consistent speed so you have a nice looking weld. This will come in time...give yourself a break in this learning curve. Aluminum Boat Welding takes a little time to get the feel for your equipment. One more thing that can help you is,try to keep what your welding in a stable position. Stop it from moving around so much. We used a lot of metal C-clamps for this.
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