Spoolgun welding of Aluminum

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I started playing around with the spoolgun on my Lincoln SP250.  but I have really no idea how to get the best welds with a spoolgun as I never used it much..  Hoping the guys here who do a lot of spoolgun welding can shed some wisdom on the subject..I do know that you always push the spoolgun whenever possible.. also 1/2" to 3/4" stand off is what I have seen as a range.  Just wondering with an adjustable nozzle should the tip be recessed if the spoolgun is into Spray Transfer mode like it is with spray transfer on mig and flush or stick out when in short circuit mode?   (the guide for my Magnum SG says that 10 ga and down is done is short circuit.)would like more input: 1:  travel speed2:  bead appearance, 3:  Material prep. Is it the same as when you are doing Aluminum TIG? 4:  Recommended settings for voltage and wire speed.  as it seems to vary a lot with some machines.   5:  Short circuit vs spray transfer.  Can you short circuit Thicker material. if so when/why..The guide given by Miller's calculator was pretty accurate for my Powcon/Profax setup but seems way high for my SP250 power source.  Interesting that the spoolgun manual I have lists the setting for a SP200 machine at 18-23 volts yet on the SP250 its listed at 16 volts for the same setting.   I tried 23-24 volts and can do 100% wire speed but its crazy fast and hot..  I find my machine hits spray transfer around 20-21 volts with around a 300ipm wire speed.    practice on some 3/16 plate produced nice welds that were in the SC/globular mode on 16vSo lets see some of the pro's weld pics with details on speed, voltage material thickness, wire etc.. Please  Once I have some guidelines, I will try them and post uup mu own picsTiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:I will be watching this thread, I would like to know about using a spoolgun also   The only time I have used one was on 1/4" and had a hard time getting it set right, seemed to weld too cold or it turned into a liquid Airco Ac/Dc 300 HeliwelderMillerMatic 200 (stolen)Miller Maxstar 150STLMiller AEAD200LE (welding and generating power) Hobart MIG
Reply:I played with my spool gun when I first got it, I guess just to see if it worked. Haven't touched in about a year.Here are some pictures of .030” on 16-GA corner joint. Attached ImagesDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:jody just did a video on spoolgun .you can find it on his site or youtube. showed how much results varied as the temp of the work piece warmed up while welding.miller thunderbolt 250vlincoln square wave tig 175 prolincoln idealarc mig sp250everlast tig 210EXTeverlast power plasma 50chicago electric (hf) 130 tig/90 arcchicago electric 90 amp flux wire3 sets oxy/acet
Reply:Originally Posted by boatbuoyjody just did a video on spoolgun .you can find it on his site or youtube. showed how much results varied as the temp of the work piece warmed up while welding.
Reply:I am curious about this subject myself.I don't have a spoolgun but I do have the push/pull gun on my Lincoln PowerMig350MP. How would using a spoolgun be different from my gun? The material being the same, the settings should be the same, no?Lincoln Power Mig 210MP MIGLincoln Power Mig 350MP - MIG and Push-PullLincoln TIG 300-300Lincoln Hobby-Weld 110v  Thanks JLAMESCK TIG TORCH, gas diffuser, pyrex cupThermal Dynamics Cutmaster 101My brain
Reply:Hope this helps:We also have a SG magnum for our Lincoln 255 mig. The best way for it to weld good without any issues is with the contact tip flushed with the nozzle. 1/2" -3/4" is about right for stand off, if you think about it, when the tip is recessed and you stand off is 1/2"-3/4" in reality it becomes 1"-1/4".
Reply:Not sure how helpful this will be.  Ran these beads with the Spoolmatic 1 off the Bobcat 225G Plus a long time ago so as best as I can remember . . .Set to CV (obviously)Gas 100% argon (obviously)Reverse polarity (again obviously)Voltage set to MAX (28V)WFS at 6 (of 10).035, 4043 wire3/8" thick extrusion - no idea what alloyOutside corner - single passInside corner - 3 passesMM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Originally Posted by Joker11I am curious about this subject myself.I don't have a spoolgun but I do have the push/pull gun on my Lincoln PowerMig350MP. How would using a spoolgun be different from my gun? The material being the same, the settings should be the same, no?
Reply:Originally Posted by AsolisHope this helps:We also have a SG magnum for our Lincoln 255 mig. The best way for it to weld good without any issues is with the contact tip flushed with the nozzle. 1/2" -3/4" is about right for stand off, if you think about it, when the tip is recessed and you stand off is 1/2"-3/4" in reality it becomes 1"-1/4".
Reply:What?2600+ posts about how great this or that welding machine is, how to do so many things, etc, etc., and you can't figure out what settings work for you with your equipment.And some question why I'm "short" with some posters.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Hey Jay have a great Thanksgiving.........  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Originally Posted by SundownIIIWhat?2600+ posts about how great this or that welding machine is, how to do so many things, etc, etc., and you can't figure out what settings work for you with your equipment.And some question why I'm "short" with some posters.
Reply:Originally Posted by soutthpawBeing that u can't keep your mouth shut why don't u go stuff it with a turkey....  Happy Thanksgiving.. :screwy:
Reply:I've found that the settings charts are starting points only. EVERY different weld (meaning different metal thickness, wire manufacturer, alloy, gas flow and position) with the spool gun requires some practice beads to get the setting just right. Try to get it set on the cold end of spray transfer for the best balance of bead appearance and burnback resistance. The thing to look for is spray transfer with a bit of wire stickout, meaning that the spray should not be emanating directly from the contact tip, but there should be a bit of wire showing out side the tip before the spray starts.Ian TannerKawasaki KX450 and many other fine tools
Reply:Originally Posted by soutthpawGod, some people are just natural born pricks...  I can figure it out but realized their was not really a spool gun mig technique thread here.   Like I said, I don't do much Al work so experience is limited.  THE IDEA OF WELDING FORUMS IS TO LEARN AND HOPEFULLY PICK UP SOME TIPS AND HINTS FROM OTHERS THAT USE A SAID PROCESS OFTEN.   Thus shortening the learning curve.  This thread is not just for me, I though that others could benefit from the info too.  Being that u can't keep your mouth shut why don't u go stuff it with a turkey....  Happy Thanksgiving.. :screwy:
Reply:Here i was looking foward to this thread as there is not a lot of good spool setup related info out there. My expirence is limited to a 250dx, wc115 and 30a gun.  Its finniky to set up and far from ideal i'm curious what it would weld like on a cv source but theres no contactor in the wc.Is there a general rule of thumb for setting the run in speed on the wc?Briggs weldnpower 225/210/cvLn-25 suitcaseMillermatic 130
Reply:Southpaw, you asked for a response from those that do alot of spoolgun work. Im sure SD III does and he gave you a response.SD III , where the frock have you been? Southpaw thinks that PULLING with mig gives better penetration because he works on thicker stuff. Can you enlighten us?
Reply:Originally Posted by InsanerideSouthpaw, you asked for a response from those that do alot of spoolgun work. Im sure SD III does and he gave you a response.SD III , where the frock have you been? Southpaw thinks that PULLING with mig gives better penetration because he works on thicker stuff. Can you enlighten us?
Reply:Originally Posted by InsanerideSouthpaw, you asked for a response from those that do alot of spoolgun work. Im sure SD III does and he gave you a response.SD III , where the frock have you been? Southpaw thinks that PULLING with mig gives better penetration because he works on thicker stuff. Can you enlighten us?
Reply:Hey DJ,Pulling or pushing on steel is of personal preference. Pushing while welding on alum ESPECIALLY with 5356 lifts the smut as you are traveling and gets you better penetration. If you want added smut control and penetration while pushing, add helium. However more magnesium may burn out of the 5356. Don't forget to look for that arc and keep it in the root. Right now I am using Argon75/he25 with good results and lower porosity than straight argon. Might try 50/50 but don't expect a big difference seeing how the mix is a bit pricey.My experience with spoolguns and alum has been dismal. On a standard mig without adjustable run-in and arc sensing only allowed me to start the arc or get a decent bead formation. Run-in control feeds the wire slowly until an arc starts then speeds up to continuous welding parameters.  I paid a pretty penny for my alum migs and the prices for run-in capable units are coming down in price.Maxal just released alloy 4943 to the public at the Fabtech show in Vegas. They are sending me sample tig rod for testing and if happy I will demo some in the mig. It may have some better starting characteristics and lower smutting and porosity than 5356. I will post a pic next post.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: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:Originally Posted by 7A749Wonder how much a roll of that stuff costs.....
Reply:Originally Posted by 7A749Just may do that Terry. If its free, why not!I have like five boxes (cases) of 1# spools both 5356 & 4043 I got for $20 a piece from a place closing their doors a few years back. They gave me two additional 12" rolls of 4043 for free. I have an XR setup now & can use the bigger stuff. I think I'm going to put my better 30A gun on the cabinet & sell the gun off from it as a spool gun.I got that & a pulser in a straight across trade for a refurbished 60 series feeder earlier this year.Don't think I'll be running out of wire any time soon.........
Reply:Hi. Since we are on topic for spool guns, does anyone have experience trouble shooting a 2035 gun?? Wire does not feed and having trouble to find the cause??   Any help or suggestions would be greatly appreciated.ThanksdurochCame up with another question.  If welding on those big 1" thick aluminum pieces,  should the passes all be stringers, or can you weave the cover passes?Tiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:Originally Posted by soutthpawCame up with another question.  If welding on those big 1" thick aluminum pieces,  should the passes all be stringers, or can you weave the cover passes?
Reply:Originally Posted by shovelonWeaves tend to undercut at the toes and is ok for filling. I have done weaves over roots, then grind them for apperance. Lance would use stringers and lots of them. Hey Brosky, how did you like the pulse action with SharpArc? I heard it and ran away.