Aluminium Production - what welder???

admin

Setting up a production run of products in my business. They are all going to be made from 32 OD 3mm WT alluminium round tube. Joins will be crimped end pieces. I have produced similar products with mild steel 25OD 1.6 WT with a 200 amp Mig Cebora welder. Starting out this line i set this welder up with a teflon liner, U roller etc etc and feed is fine. The problem i am having is that to perform a normal weld as i would have with steel, the wire speed has to be increased (almost doubled) and this produces a cold weld. With the Voltage cranked up a bit, i can get the last section of the weld to almost flow - not quite. So other settings i tried are trying to spray arc (i think) by cranking the voltage right up and laying a straight weld without any weaving to create the bead. This provides an acceptable finish, however the downfalls are - extreme temperature, causing blowthroughs when i flip the product and weld the other side, or blow throughs when the gap is slightly increased if the position is out a little. So my question is: can i achieve a result with this machine that will be consistent in poor conditions (ie. large gaps, hot and cold pieces to be welded, and with an average grade welder operating). I have been demonstrated a dual pulse mig and it left a brilliant finish, very easily but these are not cheap. Tig is out of the question as this is a production line product where i need efficiency. Any tips as to if my machine can do the job, or if not, what machines (specifically) are recommended?Thanks in advance.
Reply:Millermatic 350P, with push/pull gun.  It's called the "alum-pro" package I believe.2002 VW Golf TDi1994 Audi S4
Reply:I have to 2nd the Miller 350P alum-pro.   I played with one, makes a spool gun look like a joke.Lincoln 300 Vantage 2008300 Commander 1999SA250 1999SA200 1968Miller Syncrowave 200XMT350MPA/S-52E/xr-15Xtreme 12vs Millermatic 251 w/30A  Millermatic 251 Dialarc 250 Hypertherm 1250 GEKA & Bantom Ironwokers
Reply:Make it X3 on the 350P with a push pull set up.Disclaimer; "I am just an a$$hole welder, don't take it personally ."
Reply:X4 on the Millermatic 350P with Python or AlumaPro push-pull gun.  Other alternative would be an Invision 350MPa or XMT 350MPa with an XR feeder and Python or AlumaPro push-pull gun, or a Cobramatic feeder with Python.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Pulses spray will do what you want, dual pulse is not needed, but looks pretty.Push pull gun will save you a LOT of headaches.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:what are the advantages over spool gun? my lincoln spool gun has impressed me with its trouble free feeding and nice sound welds . A freind upgraded to push pull cobramatic and the gun seems big and heavy to me not much of difference compared to prince spool gun in wieght
Reply:The problem so far is the Miller does not seem to come over to Australia in that model yet? I am waiting on WIA (Welding Industries Australia) to call me back to see if they do bring it over.Can someone explain to me what the difference in results would be from a dual pulse or single pulse? I checked the other day with the welding supply firm of Cebora to see if I really needed the dual pulse and he seemed to think it was necessary.
Reply:Look here, pics of pulse on pulse. http://weldingweb.com/vbb/showthread.php...spray+aluminumDavid Real world weldin.  When I grow up I want to be a tig weldor.