Trying Aluminum - help

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I am trying to learn to weld aluminum. My MM 140AS is actually feeding fine after some adjustments and new drive roller. My beads aren't great, but I can work on that.My question is I get lots of blue dust and soot. I am using 5356 with straight Argon set at 30 and cleaning the work piece very well with stainless steel brush. What am I doing wrong?Burt _____________________Miller Syncrowave 250Millermatic 211Miller 375 Plasma Cutter Hobart Handler 12010FtDrillBit.com
Reply:You're not doing anything wrong, it is just that a 100-140A machine is underpowered for mig aluminum. I mean, YES, it can be done with some success. But you are treally up against the wall with that unit. If you were say using a 200-225A machine, you would have a much better start, and you could run in spray transfer instead of short circuit arc. That is a lot of where the dirty welding comes from with the aluminum. If you work on a 1/8" thick piece, you may get some spray going, but not full on spray transfer. You will see when the bead lays down well, and the heat is enough to go proper, the welds will clean up, and there will be less soot.And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:Hi Rojodiablo.Thanks for the reply. OK, I have to show my ignorance here, but I have never really understood when the books talk about "spray transfer" or "pulsed transfer" exactly what that means or what do you do different to create them? When I am welding mild steel, I just have the wire sizzling and a good arc. Again, it may be my small machine is not capable of doing spray transfer.Any information is appreciated.Burt _____________________Miller Syncrowave 250Millermatic 211Miller 375 Plasma Cutter Hobart Handler 12010FtDrillBit.com
Reply:Originally Posted by wb4rtHi Rojodiablo.Thanks for the reply. OK, I have to show my ignorance here, but I have never really understood when the books talk about "spray transfer" or "pulsed transfer" exactly what that means or what do you do different to create them? When I am welding mild steel, I just have the wire sizzling and a good arc. Again, it may be my small machine is not capable of doing spray transfer.Any information is appreciated.
Reply:Hi, Rojodiablo.Thanks for the youtube link - both of those help. I watched them several times in order to really see what is going on in the arc.I have to wonder how they made the video?I'm going to keep trying until I can make a decent aluminum weld.Again, I appreciate your help and information.Burt _____________________Miller Syncrowave 250Millermatic 211Miller 375 Plasma Cutter Hobart Handler 12010FtDrillBit.com
Reply:WRONG WIRE.  5356 is used for welding Aluminum/Magnesium compositions.  Doesn't work worth crap on straight aluminum grades.   Use 4043 wire.  You'll love the difference.  100% argon is the gas to use.  Also, be sure to keep your shielding gas just that.  Shielded.  If a strong wind comes along, you're beads will look like Chicken S***.  I do a lot of aluminum dump body repairs, most have to be done outside, if breezy I have to crank up the CFM on the flow meter.  Being Argon is expensive and consumed rapidly, I also adjust my hourly rate when that happens.  Sometimes I can't weld at all as the wind is too strong.  Good Luck with the new wire.
Reply:paweldor,I'm sure it's just a typo but I imagine you would go through alot of argon flowing CFM instead of CFH.  But then, if the wind's blowin' hard enough...MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Originally Posted by duaneb55paweldor,I'm sure it's just a typo but I imagine you would go through alot of argon flowing CFM instead of CFH.  But then, if the wind's blowin' hard enough...
Reply:Originally Posted by paweldorWRONG WIRE.  5356 is used for welding Aluminum/Magnesium compositions.  Doesn't work worth crap on straight aluminum grades.   Use 4043 wire.  You'll love the difference.  100% argon is the gas to use.  Also, be sure to keep your shielding gas just that.  Shielded.  If a strong wind comes along, you're beads will look like Chicken S***.  I do a lot of aluminum dump body repairs, most have to be done outside, if breezy I have to crank up the CFM on the flow meter.  Being Argon is expensive and consumed rapidly, I also adjust my hourly rate when that happens.  Sometimes I can't weld at all as the wind is too strong.  Good Luck with the new wire.