Can I spray aluminum with less power than I would need for steel???

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I don't think I have the power to tig what I need to do for an aluminum dump body. And, frankly from what I've been reading using a mig gun seems a bit easier and much faster for adding "T" channels on the side of the dump body. The channels are for allowing the customer to add for side planks so he can carry more mulch. Oh yeah, I'm hoping/thinking it takes less power to spray aluminum compared to the same size steel wire. Yes/No????Thanks in advance for your help,PeteEverlast  i210 with 200a spool gunEverlast i140eLOTOS LTP5000D Non-Touch Pilot Arc "Things are never so bad that they can't get worse...."
Reply:Pete, the real simple answer is "NO", it typically takes more (power wise) to spray aluminum than steel and it is relative to material thickness and not so much wire diameter, although that is a factor as well. Due to how quickly aluminum disperses heat it takes more to make a sufficient weld on it. So 1/4" aluminum will require more voltage/amperage to achieve a proper weld. That's the short of it. Plenty more could be written to explain it in more detail but it won't change the results. Best regards, Allanaevald
Reply:Originally Posted by aevaldPete, the real simple answer is "NO", it typically takes more (power wise) to spray aluminum than steel and it is relative to material thickness and not so much wire diameter, although that is a factor as well. Due to how quickly aluminum disperses heat it takes more to make a sufficient weld on it. So 1/4" aluminum will require more voltage/amperage to achieve a proper weld. That's the short of it. Plenty more could be written to explain it in more detail but it won't change the results. Best regards, Allan
Reply:You can get a helium/argon mix tank to add some more punch to your tig.Or buy a larger mig and learn spool gun aluminum - which also has a learning curve to it.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Mig with 5356 is the way to go. If you have 180-200 amps you should be in the ball park. You could use a weed burner on the aluminum to preheat it so you could use less amps.  Tig is going to be too slow to make any money .  If you do use tig use 5356 filler it will give more strength than 4043.
Reply:It can be done, I've done it in the past with great result. Pre heat with a mapp torch, and it don't take much. Run a pass using 1/16" filler. When you're done let it cool just a bit and now you can run over that first pass with 3/32 filler and you will be fine with zero over heating of the material(haz). Timing with cooling is critical, just as with your first pass with a 1/16 filler.. First pass will give a small bead profile, yet give you the pre heat you need to slug in the 3/32. It's a little more time consuming but it can be done. Don't practice on a project, get some scrap and give it a go. When you're ready you will know it.I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:You can also use an argon/helium mix to impart more heat in the arc gap on same voltage. Just be sure to adjust wire speed accordingly.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:You guy's are being a great help. Part of why I asked is I saw "Jody" using a Hobart 210 to "spray" (he said) .035  an aluminum job. I had an MVP 210 and for all Practical purposes it really wouldn't spray   023 steel wire consistently, even running 95/5 mix.NOW, what should I do:1. Can I get a decent weld from “short circuit” welding the aluminum.2. Can I finesse a bearable spray from my Everlast 140, which welds .035 steel wire “better” than the MVP did.3. Do I get a Helium mix.Again, I appreciate the time you guy's are taking to help an old “geezer” of 65.PeteEverlast  i210 with 200a spool gunEverlast i140eLOTOS LTP5000D Non-Touch Pilot Arc "Things are never so bad that they can't get worse...."
Reply:Aluminum mig is spray only.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:I suggest 4043 wire for truck beds and trailers, they twist and move around too much for 5356 causing stress cracks. At least thats my experience anyway.JonLast edited by welderj; 02-21-2016 at 08:49 PM.Yeah, I know, but it'll be ok!Lincoln Square wave 255Miller Vintage mig30a spoolgunThermal Dynamics Pacmaster 100xl plasmaSmith mc torchEllis 1600 band saw