Help with Miller XMT 350 MPa Aluminum Welding Setup

Wed, 24 Nov 2021 07:51:32 GMT

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Hello everyone, I was hoping I could get some direction on our new welding setup we just purchased. We needed to get a setup for welding aluminum so we went with the Miller XMT MPa, S-74 MPa Plus wire feeder, and an XR-Aluma-Pro Plus gun. We're running it with 100% argon and ER5356 .035" wire. We got a Fume-Dog extractor for worker safety and I built a new welding table for it with our Millermatic 252. One of the other managers here was a welder before becoming an electrician and he tried setting up the new system, but it's sophistication surpasses his knowledge. We're having trouble getting proper penetration on the aluminum as we weld so it's basically just spraying onto the work pieces and only superficially joining them. Very similar to a CAD weld of copper to steel. I can break the welds with some effort. Essentially what we're trying to do is weld 2" x 2" x 1/4" angle to the center of a 10" x 10" x 1/2 plate as a mast for conduit supports. We've tried a myriad of settings under both pulse mig and standard mig and can't seem to get it dialed in to penetrate that 1/2" plate for a good weld. We've preheated the pieces with a torch and tested the temp with a temp stick to make sure it was hot. I'm convinced the settings on the welder are what needs addressing. Has anyone got any experience with this setup and can give me some pointers?
Reply:Does it show average amps during welding on that setup?I had an older XMT setup with pulse pendant and it worked well but everything was governed off wire speed, it wasn't sophisticated enough to work its own wirespeed out. If you're not getting the penetration you need more amps, and to get more amps you need more wirespeed.Murphy's Golden Rule: Whoever has the gold, makes the rules.
Reply:What are your settings now? First off you would be better suited to 3/64" or 1/16" wire for that. With .035 I would think you would need around 600 ipm to get enough amperage.

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