arc welding aluminum

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Ive got an Linde 225 AC only welder and a nearly unlimited supply of .125 aluminum sheeting.can i weld aluminum with that machine, or am i just asking for trouble.  I realize arc welders are not ideal, but i'd like to learn how to make some "farm reparis" on aluminum if needed.  We have a big horse trailer made of aluminum ... and horses always break stuff.total novice here, so i've got my whole life to learn bad habits any thoughts?
Reply:Hello Meborder, the machine you have is not an ideal choice for welding on aluminum. A wire feed machine with 250 amps + equipped with a spool gun or push-pull system is better suited to your requirements or an AC capable tig welder with 250 amps+. There is plenty more that could be discussed or explored for your needs to repair an aluminum horse trailer. For the safety of the horses and other motorists avoid the arc welding route. Good luck and best regards, Allanaevald
Reply:Lean to weld stick well 1st. If you can not control the arc and puddle alum stick will be a nightmare. It's significantly harder to run than "normal" rods. 1/8" alum is on the thin side for stick as well. It's doable, but will require more skill. Rick V did a thread on alum stick welding. While his skills with stick were not all that good at the time, it will show you what you can expect with limited skills. I seriously doubt you will be happy with your results with this..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:Hi Meborder,Alas I found that an AC stick welder will not work at all with aluminum stick electrodes - it just makes sparks - no arc.  You require a DC or AC/DC arc welder to use aluminum stick electrodes - on DC(+).  Also, 1/8 inch (0.125) is about the thinest aluminum I could weld with stick.References:http://weldingweb.com/vbb/showthread.php?t=45197http://weldingweb.com/vbb/showthread.php?t=58760Last edited by Rick V; 01-09-2012 at 02:03 PM.Rick V 1 Airco Heliwelder 3A/DDR3 CTC 70/90 amp Stick/Tig Inverters in Parallel1 Lincoln MIG PAK 151 Oxy-Acet
Reply:Rick is dead on on that one. DC+ is the only way you can do it and 3/32" rod is the smallest you can go. i have done 1/8" sheet with it. it ain't purdy till you chip the slag and then unless you had a few  or use a brown paper bag it still ain't purdy. but if you got good control of your rod and go like heck it will get it done.225NT bobcatAEAD200LEScott 125mm175, mm252 w 30A, PT225mm211, TA 181iHyper Therm 380, cut master 529100X & XX, Digital Elite6 Victor setssmith little torch, meco midget kalamazoo band sawsteel max saw evoulution circular saw
Reply:Originally Posted by aevaldHello Meborder, the machine you have is not an ideal choice for welding on aluminum. A wire feed machine with 250 amps + equipped with a spool gun or push-pull system is better suited to your requirements or an AC capable tig welder with 250 amps+. There is plenty more that could be discussed or explored for your needs to repair an aluminum horse trailer. For the safety of the horses and other motorists avoid the arc welding route. Good luck and best regards, Allan
Reply:you could always get a high frequency setup, and a tig torch and use your machine to power it.Dynasty 200DXPassport plus w/ spoolmate 100victor 315c oxy/(act and prop)Miller digital elitemilwaukee power tools
Reply:x2 on what Rick said and I did give the stick rod a try also..   not sure how much you value your horses but If you are anything like my sister, they are her "kids"  so get it professionally repaired.  unless you want some aluminum piece breaking off somewhere on the highway and potentially spearing one of your horses.  I get the impression you ar referring to fixing attachments etc inside the trailer and not doing structural repairs on it...  which then put lives of everyone else on the road around you at risk...There is no cheap way to weld aluminum properly.  you are into a better part of $1000 even with a machine from someone like Everlast.  once you buy a tank, rod, fill it, etc.  also how much value do you put on your time?   it will take 100's of hours of practice to get proficient at TIG welding aluminum.  Less learning time and about the same cost for MIG but MIG welding Aluminum is for 1/8" and up, not for thin stuffLast edited by soutthpaw; 01-09-2012 at 02:54 PM.Tiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:Dont waste your $, time and effort on a process that no one uses because it just doesnt work well. Your ac machine is not going to od the job. Even stick welding al with a dc machine produces extreamly poor results. The rods are expensive and you need thick material to use. Your .125" 1/8 material is way too thin. You will do nothing but blow holes inthe material and ruin it.Rick V spent a lot of time, $ and effort in a large experament trying this and he never produced one weld that I would call acceptable quality.If you need some aluminum welded, bring it to your local weld shop and they will AC tig it. The way it should be done. You will much more pleased with the results and the cost.JasonLincoln Idealarc 250 stick/tigThermal Dynamics Cutmaster 52Miller Bobcat 250Torchmate CNC tableThermal Arc Hefty 2Ironworkers Local 720
Reply:Rick has done extensive work on this subject and knows about what he  says!  Bob
Reply:I concur. Stick welding aluminum is "Witchcraft".  It should only be used for non-structural emergency repairs.  For anything structural, Tig or Mig is the way to go.But, if you must use this process, try this...As with all aluminum welding,  clean the hell out of the aluminum within 15 minutes of welding, preheat the material 150 - 200 degrees.Always weld in the flat position, with a slight (5-10 deg.) angle of the workpiece.  Weld progression will be uphill, this way gravity will help keep the slag behind the arc.  Hold a short arc length.  Make small circular oscillations, with the rod at about 10-15 degree angle in the direction of travel.Do a T joint and then do a bend/break test of the joint.  If the metal folds over without the weld breaking, then the weld is stronger than the material.I suspect what you will see is the weld breaks down the center and the fractured surfaces look like swiss cheese.Good luck!Weldtek
Reply:yeah ... sounds like im just SOL ... which is fine.nice to know what can and cannot be done with the eqiupment i have.  Looking closer at the rods i found, i noticed that they were for DC only, so that pretty much rules out my equipment.intrigued about turning it into a TIG ..... but i can't see buying serious equipment just to play.maybe some day i can pony up to a Stick/Mig/Tig machine ... but that's many years off.for now, i'll just consider myself a magnet and stick to steel.thanks for all the input!  your efforts were not wasted or unappreciated!
Reply:Originally Posted by Meborderfor now, i'll just consider myself a magnet and stick to steel.
Reply:Originally Posted by turkyou could always get a high frequency setup, and a tig torch and use your machine to power it.