What would happen if I used 75/25 gas for thin aluminum diamondplate?

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I want to build myself a custom flightbag (briefcase) out of thin guage alum diamondplate. I want to use alum angle for interior frame. I dont have a spoolgun. If I keep the gun really straight and use my 75/25 bottle could I make a few alum welds here and there with my PM180c?  What are the chances this would work? I don't want 2 bottles for cost reasons. Is there a mix that works for both steel and alum?Lincoln PowerMig 180cVictor O/ABandaids and aspirinI don't know what I don't know!?
Reply:You get a black bubbling mess. Wire jammed up in the tip and birds nest in the welder.100% argon works ok for steel and works well for AL. 100% argon with mig is only Ok for steel, 75/25 is better.Last edited by Timberwolf; 10-24-2008 at 12:05 PM.Lincoln PT185 TIGLincoln 175 MIGLincoln 240 amp AC StickLind Needle Arc plasma welderPlasma cutter, soon???
Reply:PM180 and aluminum?Get the SG100 spoolgun (about $200) and a small tank of argon.  The SG100 is plug-n-play with the PM180 (and other machine from Lincoln in that era/class/style/whatever) and you need plain argon to shield the aluminum while you are welding.Without good shielding (flow and the right gas), when the arc hits the aluminum and the metal melts it will turn into "a black bubbling mess" from oxidation and interaction with the air.Is there a gas that can be used too shield steel and aluminum when they are arc welded?Sure, plain argon with the GTAW (aka TIG) process.  GTAW uses argon for almost everything, and what it doesn't use plain argon for it then usually uses an argon-helium blend.For GMAW (aka MIG), different metals and different fillers and different welding modes often use different shielding gases.  There really isn't any 'one' gas that can be used for GMAW shielding everything.Last edited by MoonRise; 10-24-2008 at 12:39 PM.  The best laid schemes ... Gang oft agley ...
Reply:Aluminum brazing alloys do exist which could be used with your OA torch; information and supplies should be available at your LWS. If you go this route, practice with scrap materials before trying it on your project.
Reply:Try it and see? Best lesson you could get.
Reply:how many times have we gone over this same question?  try and report back