MIG welding aluminum issues

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So I have a 210 Hobart welder and I've decided to try and learn to weld aluminum. I've done some google searches but no matter what I do, it doesn't seem to work. I understand that it's supposed to work as a "spray transfer" but the spray seems to be coming out and looks like a flame straight from the contact tip. Naturally I assume it's the wire speed but I turned it all the way up and it still does the same thing. I can get it to start the spray closer to the material for a little while in the beginning but then it goes back up to the tip, even at full wire feed. If I'm not mistaken, this machine should easily weld 1/8" thick aluminum, correct? Oh and yes, I'm using a spool gun with 100% argon.
Reply:The Tip to work distance is critical when welding aluminum.You can also adjust the tension at the Spoolgun through the top.Could be a bad jug of Argon.Can you post up some photos of the welds that you have been able to make?The HH210 is supposed to be an excellent welder on AL.Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:The argon is brand new. Guess that doesn't mean much... Though my thinking is it must be the tension cuz shouldn't the wire hit the workpiece at full wire speed when the voltage is low? I'll play with it again tomorrow and see if I can get some pics. Also the aluminum turns black around the weld area. Is that normal?
Reply:Originally Posted by EcondronThe argon is brand new. Guess that doesn't mean much... Though my thinking is it must be the tension cuz shouldn't the wire hit the workpiece at full wire speed when the voltage is low? I'll play with it again tomorrow and see if I can get some pics. Also the aluminum turns black around the weld area. Is that normal?
Reply:You can minimize sooting by pushing the wire into the puddle instead of pulling."If you live in Sacramento you have seen my work."
Reply:Used a Miller 350P  Mig Machine when they first came out which was my first time MIG welding aluminum and was very impressed on how nice the weld looked being used to looking at TIG welds.  The push-pull gun is really nice....  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:What size wire? What thickness? Alloy? Need more info.Ian TannerKawasaki KX450 and many other fine tools
Reply:are you doing this with a spool gun or the regular mig gun, If its the latter, be sure u are using a teflon liner, aluminum drive rolls etc. and keep mig gun cable as straight as possible.  if you are at 100 wire speed, try turning the voltage way down..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:.035" wire diameter with 4043 alloy wire. If you know the machine, I've had it set to 4 (out of 7) and 100 (Out of 100) and the wire is burning back and gooping up on the tip. Could it be a faulty spool gun? And I am using a spool gun.
Reply:If you are burning the wire back, your voltage is probably too high. What i would recommend, is to start over at the recommended settings for material that is a bit thinner than what you've got and slowly work your way back up.Also, do you have the polarity correct?Ian TannerKawasaki KX450 and many other fine tools