Spool Gun issues

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I have been having some issues with the wire burning back in the tip sticking melting.180 Miller 100 series gun. I use a helium-argon mix and a straight argon, seems to not make a dif. Now if Iam on a long bead and with the hel-arg mix I can bend the tip because of to much heat. Other then a bigger machine to eliminate the helium I dont use that mix often just on the thicker stuff couple times a yr.any ideas on wire burn back in the tip?Change wire speed or change my style of welding when finishing the bead? I have went up a tip size larger then the wire on advice from someone still no dif. Thanx Dale Attached ImagesMiller 250DX HTP 221 DV AC/DCHenrob O-A Miller 180 MigMiller 150 Inverter   Hobart 10,000 Welder-Generator   Have a good day!!!
Reply:I don't like them even tho I own one (never even used it) and have one at work and you would have to put a gun to my head to use that one as well, but straight argon, long stick out and only push bud!I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Welcome to aluminum MIG welding. Step 1: buy lots of tips.Step 2: set the voltage just high enough to prevent popping or stubbing. Too much voltage for the wire speed will make it burn back into the tip.Step 3: Make sure you are using tips made for aluminum wire. They have a larger hole than tips for steel. Aluminum wire expands when it gets hot, and it will stick in a tip meant for steel.Step 4: Light-duty guns will overheat on long welds. Let the gun cool off if it seems hot.Step 5: same as step 1.  JohnA few weldersA lot of hammersA whole lot of C-clamps
Reply:Hello power, silicon-based gave you a lot of the specifics for dealing with the issues you are having. In particular the difference between aluminum tips and standard tips is a big one. Gas type can have some bearing on tip life too, straight argon will provide the most integral cooling as a shielding gas, although, I realize you may be using the helium/argon mix to help with power issues. To go along with natural cooling relative to type of shielding gas, maximum recommended flow rates(not to the point of creating turbulence) will help with cooling of the tip and associated parts. Since your machine doesn't have post-flow capabilities, you may attempt to get in the habit of only releasing the trigger enough to stop wire advancement and welding but still allow for post gas flow to promote tip cooling and protection. Good luck and best regards, Allanaevald
Reply:And if you were not aware, buy lots of tips.