Aluminum Mig Welding Creating High Quality WeldsAluminum Mig Welding can be used in all positions, and it creates high quality welds. Argon Gas (inert shielding gas) was used for building our boat it is virtually used for all metals except for steels. Each type of gas has an effect such as bead sizes, penetration, and welding speed. Argon (Ar) reduces the spatter causing a squeezing (narrowing) of the arc. Argon is heavier than Helium and uses less gas to protect a weld. Watch out for your gas flow rates, too much gas causes the weld to become contaminated. Too little gas the weld becomes contaminated and porous. The manufacturer gives the proper flow rates, it can be used at all wire speeds.
Welds that are not in a normal flat position make sure you wear cotton clothing. The filler metal spatters and sparks fly which can give you pretty bad burns.
This copper nozzle will wear down in time and must be replaced. Most welding processes require you to control the arc length, welding, speed, spool gun angle, so you will have a good quality weld. The gun angle and speed gives you your appearance of the bead width and penetration.
The wire will arc (melt) as soon as it touches the metal your welding. You will move the gun forward when you see a proper width or arc pool. Aluminum Mig Welding Tip:
Make sure that if you have to make more than one pass to fill a weld groove, clean it before making second pass.
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When you are welding with the right amount of shielding gas flowing, a rapid crackling and hissing sound will be heard. Too little gas will make a popping sound and spatter.Increase your gas flow rate when you are welding horizontal, vertical, and overhead positions.
On the spool gun there is a gas nozzle located at the end of the gun. It is made out of copper, also a very good conductor of heat.You can pick a general purpose nozzle just watch out for the build up that likes to build up inside the copper opening. That can also cause bad welds...pick it clean.