MIG welding aluminum(heat control)

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Hey everyone, or more specifically, those with MIG welding aluminum experience.. What are some techniques you use to control heat? I just got my Aluminum add-on kit for my lincoln MIG machine so I tried it out a little bit today. I did ok for the most part, but of course as I got towards the end the puddle was getting sorta large... I can TIG weld aluminum with no problem, I'm even certified, but MIG is a whole different ballgame it seems. I am gonna play with the settings a little bit more tomorrow to fine tune it. The specs are 1/8" plate ( I'm assumin a 6xxx series extrusion?? I bought it at home depot), Fillet weld, straight argon, .035 superglaze 4043 wire, @ about 135A cuz thats as high as my machine goes.Any tips? I think I may be getting just towards the end of the range with the 1/8" plate and my machine(SP135). Maybe it's time for an upgrade!oh, and just to be sure..stitching aluminum is a  , correct?
Reply:nobody??
Reply:just hang in there,,  somebody will chime in sorry  i Tig, so not much help in the mig but it is a different game mig welding alum., i use the med. heat(30-130)  on my idealarc 250 have tryed mig but never had good luck with alum
Reply:From my experience with a Weld-Pak 155 & a Pro-Mig 175 on aluminum...Under 1/8" thick, you'll have difficulty avoiding burn through without making  stitch welds or very short beads.   You will still need to have your machine at at least half power.Get used to running you machine (voltage and wire) near wide open and increasing your travel time.Your ESO (electrode stick out) should be about 2 - 3 times what you're used to for steel.    I keep about 1/2" to 5/8" between the electode tip and the work.    Don't try making long welds.  Too much heat will build up and the metal ahead of the arc will start to melt.Always push your welds and avoid vertical up welding.Don't watch the arc, look at the puddle behind the arc and guage how it's behaving.   If the weld is round and tall, slow down, if it gets flat, let go of the trigger or speed up.   If the welds look rough, increase your wire speed slightly.Unless I know there's too much heat, I end my beads with a small circle to limit any cratering.Plan your work so to keep the torch cable as straight as possible to avoid feed problems.   5356 wire will feed better than 4043.    Set you drive roller tension loose such that if you block the wire at the torch, the driver rollers will slip.Good LuckThere are no small projects
Reply:Try going from near the edges in toward the middle and using a backing plate to draw off some of the heat.Smithboy...if it ain't broke, you ain't tryin'.
Reply:From my experience with a Weld-Pak 155 & a Pro-Mig 175 on aluminum...Under 1/8" thick, you'll have difficulty avoiding burn through without making stitch welds or very short beads. You will still need to have your machine at at least half power.Get used to running you machine (voltage and wire) near wide open and increasing your travel time.Your ESO (electrode stick out) should be about 2 - 3 times what you're used to for steel. I keep about 1/2" to 5/8" between the electode tip and the work. Don't try making long welds. Too much heat will build up and the metal ahead of the arc will start to melt.Always push your welds and avoid vertical up welding.Don't watch the arc, look at the puddle behind the arc and guage how it's behaving. If the weld is round and tall, slow down, if it gets flat, let go of the trigger or speed up. If the welds look rough, increase your wire speed slightly.Unless I know there's too much heat, I end my beads with a small circle to limit any cratering.Plan your work so to keep the torch cable as straight as possible to avoid feed problems. 5356 wire will feed better than 4043. Set you drive roller tension loose such that if you block the wire at the torch, the driver rollers will slip.Good Luckimagineer, thank you for the most excellent briefing on MIG welding aluminum. I have been playing around with my spool gun enough that everything you said now makes sense. I have printed this and keep it near my machine for reference. Thanks again.snoboy
Reply:Originally Posted by Shaggz00Hey everyone,  or more specifically, those with MIG welding aluminum experience.. [I]What are some techniques you use to control heat? I just got my Aluminum add-on kit for my lincoln MIG machine so I tried it out a little bit today. I did ok for the most part, but of course as I got towards the end the puddle was getting sorta large... [I]I can TIG weld aluminum with no problem, I'm even certified, but MIG is a whole different ballgame it seems. I am gonna play with the settings a little bit more tomorrow to fine tune it.The specs are 1/8" plate ( I'm assumin a 6xxx series extrusion?? I bought it at home depot), Fillet weld, straight argon, .035 superglaze 4043 wire, @ about 135A cuz thats as high as my machine goes.  Any tips? I think I may be getting just towards the end of the range with the 1/8" plate and my machine(SP135). Maybe it's time for an upgrade![I]oh, and just to be sure..stitching aluminum is a  , correct?