MIG aluminum

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is it OK to continiously start and stop my weld to keep from burning through? i tryed a bunch of different settings. if i go any higher i go right through. if i go any lower the weld just breaks up. so i weld about an inch around and then stop wait a few seconds and then go again. will this weaken the welds?  better way to weld thin edges of aluminum pipe?
Reply:Don't stop just increase your travel speed....as MIG welding AL has cold starts so if you keep stopping and starting you will have issues....what machine material etc are you using.....
Reply:I agree, go faster, with aluminum you gotta go fast.push the gun so the gas keeps ahead fo the weld, if you use a stainless steel brush to remove the oxied prior to welding you can go a little faster because your not burning it of in my opinion. how thick of material what size wire are you using? If you are welding pipe you must drill a hole somewhere because the gasess built up inside and will cause a blow out where your welding, and you will get mad because you dont know why the hell you are burning through.Nothing Ever Got Done By Quitting, Never Give Up.
Reply:remember you must spray the wire.6G zirconium 702 GTAW 2" xxheavy6G P.E.D. carbon steel GTAW 2" xxheavy3G titanium Gr. 2 - Gr. 7 GTAW up to 3/4" 3G 316L stainless GTAW up to 1" 3G carbon steel GTAW up to 1" 3G Hastalloy GTAW up to 3/4"1G tantalum GTAW up to .060"
Reply:im using a Clarke 180EN 220v MIG. the wire is .9mm and the pipe measured .08 of and inch with my digital mic.what do you mean "spray the wire"???im going to try pushing it. i had the gun slanted a little so i could see, and went along side of it. so i didnt really push or pull. is this a bad mathod???Lincoln Square Wave 175 TIGLincoln 110v flux core welder (my 1st)Clarke 180EN MIG
Reply:instead of runnging it just like hard wire (where the wire touches the puddle) turn the wire down while welding on a scrap piece and watch the wire get farther and farther away from the puddle. others are better at explaining but if the wire is going straight into the puddle it will help it burn through6G zirconium 702 GTAW 2" xxheavy6G P.E.D. carbon steel GTAW 2" xxheavy3G titanium Gr. 2 - Gr. 7 GTAW up to 3/4" 3G 316L stainless GTAW up to 1" 3G carbon steel GTAW up to 1" 3G Hastalloy GTAW up to 3/4"1G tantalum GTAW up to .060"
Reply:i noticed that. if i turned the wires speed down and let it melt higher up the wire. it would weld better, but the sound was off to me. compared to my usual non-gas flux core welding. maybe i shouldnt compare such different styles of welding...thanks for the tipskeep'em comingLincoln Square Wave 175 TIGLincoln 110v flux core welder (my 1st)Clarke 180EN MIG
Reply:Sounds like you started to spray! Psssssssssssst
Reply:I think you are getting some good advice from the guys. Usually, you don't get recommended to do "stitch welds" with mig, as the cold starts and stops are not desired. But for thin material, and sheetmetals, it can be the way to go. If the material is thin, and your welder will go into spray transfer for you, you may be able to just hustle right through your weld, and barely have to stop. Spray transfer is a very respected method for aluminum mig, and it would be less likely to leak on you if the tubing you are welding will be carrying water/ fluid, or is used to hold pressure like air lines, etc. All the starts and stops create cold spots. Which, in the real world, will hold plenty strong enough on light projects, but will not be sealed well enough for any kind of pressure vessel work.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:well, i dont want it to be weak. but the most that would be pushed through it would be 25psi of air through 2 1/2 inch piping. so im not to worried about it breaking. but i do like to do good work, weather it needs it or not. i'll work on my "spray" technique.how high should i let it go up the wire, or should i just feel that out per project???Lincoln Square Wave 175 TIGLincoln 110v flux core welder (my 1st)Clarke 180EN MIG
Reply:If you're burning through, orient your joint so you're welding verticle-down.  You'll have less chance of burn-through in that position.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:let the wire get about 3/16 or so away from the puddle.6G zirconium 702 GTAW 2" xxheavy6G P.E.D. carbon steel GTAW 2" xxheavy3G titanium Gr. 2 - Gr. 7 GTAW up to 3/4" 3G 316L stainless GTAW up to 1" 3G carbon steel GTAW up to 1" 3G Hastalloy GTAW up to 3/4"1G tantalum GTAW up to .060"
Reply:MIG + Al. = GO FAST haha If you keep stop/starting it will weaken the integrity of the weld/base metal.Certified Welding Inspector at your service...Level II Nuclear Welding InspectorLevel II Nuclear Electrical InspectorLevel II Nuclear Civil InspectorLevel II Ultrasonic Thickness Testing TechnicianCertified Smartass,and Wise Acre
Reply:sen2two, spray sounds like a wicked electrical hiss/hum.  Nothing at all like what you are probably used to hearing or feeling even.  I have trained many people on spray transfer MIG processes and the biggest problem people have is that it doesn't sound like what they expect.  Let the sound issue go and inspect the results.  You'll be pleased with the results.And travel FAST!
Reply:thanks for that tip. i didnt know about the "spray" technique while i was doing it. the welds were coming out much better. but it sounded worse than ever. i was confused...so im just going to watch the weld, and forget about the sound completely like your said.thanks...Lincoln Square Wave 175 TIGLincoln 110v flux core welder (my 1st)Clarke 180EN MIG
Reply:Guys,As the OP stated, the material he's welding is .08".  He's going to have a difficult task ahead of him regardless of technique or short arc/spray.Aluminum, less than 1/8" presents challenges for any non pulse welder.If he wants it to be strong and look good, he should try to find a friend to tig it for him.  He did mention that it would be under pressure.  25 PSI doesn't sound like much, but have you ever seen a tire blow at 25 PSI?Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:25 psi and 2 1/2" pipe....that is alot more than you would think......and at 0.08" thick is def. a TIG job.......
Reply:i did it. its not the prettiest welds ever to grace aluminum piping.but it holds up just fine to the 25psi were throwing at it.just took some practice. this was my first attempt at aluminum. the only welding i did previosuly was 110v flux core no gas welding.Lincoln Square Wave 175 TIGLincoln 110v flux core welder (my 1st)Clarke 180EN MIG