First Time Welding Aluminum. . Need Advice ?

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I just bought a new Hobart 190 with a Spool-Gun last month, and finally had time to try and weld aluminum!I'm not used to the settings on the welder yet.. I've only used it a few times on steel, and I know aluminum is harder to learn to weld. . I know: practice, practice, practice!Here's what I was using and the settings on the welder.1.) The aluminum I was welding was a piece of 1/8" scrap I had.2.) I was using .030 Hobart wire.3.) Argon was set on 20 to 25 psi.4.) Welder voltage was set on 1.. ( as low as it would go)5.) Wire speed was set on 70.If I turned the voltage up higher than 1, It would burn through the aluminum. . With it set on 1, If I turned the "wire speed" down lower than 7, It wouldn't even start a bead. (it would just start to ball up)Also, The Argon was on 20 to 25 psi. . I'm not sure what lb. I needed to set the Argon at ?. . Do I need to set it higher than 20 to 25 ?I'm not sure where I even got the piece of scrap aluminum. . I have some diamond plate aluminum that I could try and weld. . I know the diamond plate is "harder" than the scrap piece that I practiced on. Any help would be appreciated! Here's a couple pictures. Attached ImagesHobart Handler 190Hobart Spool-Gun 100Lincoln 225 ACMiller & Pipeliner HoodDewalt 14" Chopsaw, GrindersHarris O/AVictor TorchCustom Built O/A CartCustom Welding CartHeavy Duty 16 Speed Floor Drill PressPipe-BenderDrill Doctor
Reply:Those are a lot better than my first try with a spool gun Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:Much of what you said doesn't make sense. Specifically the fact you were on voltage tap 1 and burning holes on 1/8". Alum is a great heat sink, and it needs lots of voltage to weld well. On a 190 amp class mig, you should have been up near max. The manual lists tap 5, wire speed at 95. 1/ 75 is listed for 16 ga.I'm guessing you material is most likely thinner than you think it is. That or you are leaving something else out.As far as the "burn thru" on the edge, that's fairly typical with alum and mig. Keep in mind that the whole piece is heating up as you weld, and the "heat" from the arc is blowing out in front of the torch as you push it, thus somewhat "preheating" the area in front of the bead. When you hit that thin edge at the end, everything is now working against you. The piece is hot, the heat from the arc is heating the edge before you get there, you have no control over your amps except what the machine is set at... Chances are the edge will melt. You combat this by starting at the edge and welding towards the center..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Thanks for the reply! Originally Posted by DSWMuch of what you said doesn't make sense. Specifically the fact you were on voltage tap 1 and burning holes on 1/8". Alum is a great heat sink, and it needs lots of voltage to weld well. On a 190 amp class mig, you should have been up near max. The manual lists tap 5, wire speed at 95. 1/ 75 is listed for 16 ga.
Reply:Are you pushing or dragging the weld? With alum mig you push.I also just realized something. Are you cooling between welds? Bead 1 looks a lot colder than bead 8. If you are just running bead after bead, then the heat buildup in the plate explains why the material would seem "thinner " to me with your settings.Last edited by DSW; 03-03-2013 at 11:10 AM..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Videos always help meshort one:http://www.weldingtipsandtricks.com/...-aluminum.htmlLong one:http://www.weldingtipsandtricks.com/...t-ironman.htmlHope it helps,Dave J.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:Argon flow is not in lbs nor psi.  It is in either CFH (cubic feet per hour) or LPM (liters per minute).  15-20 CFH is a good starting point. 1st on WeldingWeb to have a scrolling sig! HTP Invertig 400HTP Invertig 221HTP ProPulse 300HTP ProPulse 200 x2HTP ProPulse 220MTSHTP Inverarc 200TLP HTP Microcut 875SC
Reply:My miller 210 panel recommends 35CFH 100% Argon when welding aluminum with spool gun.I've done it and it works, but I did not like the lack of control.  That's what pushed me into learning tig.With mig aluminum I found that using run-on and run-off tabs helped the weld appearance since the start/stops were off the piece.Dave J.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:Originally Posted by DSWAre you pushing or dragging the weld? With alum mig you push.
Reply:Originally Posted by MinnesotaDaveVideos always help meshort one:http://www.weldingtipsandtricks.com/...-aluminum.htmlLong one:http://www.weldingtipsandtricks.com/...t-ironman.htmlHope it helps,Dave J.
Reply:Originally Posted by WelderBillThanks for the videos! . . He makes it look to easy! One thing I noticed in the long video. . He mentioned the "sound" that he wanted! . . Don't know if that would help me with my 190 welder, But I could try and listen to the sound when I give it a try again today! Thanks!I was just wanting to know what to set my gauge on ?I have it set on 20 to 25 lb.Thanks!