MIG welding aluminum is one of the most commonly used methods of welding. There are two types of MIG welding: Continuous Feed and Spray Process. Continuous feeding MIG welding uses a continuous feed of electrode into the weld puddle. The MIG electrodes are placed in a cup, which contains tungsten which is then struck by a machine. The tungsten electrode carries the carbon electrode, which is also strikes by the machine and produces the weld.
MIG welding aluminum typically relies on using the correct equipment because of the soft nature of this wire. Without the proper equipment, MIG welding aluminum can be quite noisy with a bacon frying sound coming from the wire. In addition, the operator must have good hand eye coordination in order to control the wire speed. However, with aluminum a separate feed system is required otherwise the weld will break and bunch up along the seams. Once the correct equipment is in place, it’s a pretty darn easy metal to weld, again without a bacon fried sound.
One of the key differences between the two is that with aluminum there are no separate feeding mechanism but rather a continuous spray feeding mechanism. In order for this to work properly you must have a well-engineered airbrush system. You must also be able to accurately adjust the airbrush pressure and air flow. Because of these factors it is important to use a qualified shop vac in order to remove all of the dust, dirt and debris from the gun. The other difference between MIG welding aluminum and the more traditional welding is that the weld comes out smoother and more consistent with the spray process.
There are several factors that make aluminum the best choice when it comes to mig welding aluminum. First off the material is much less expensive. Secondly, it is more flexible and can be used for thinner gauges and is typically used for lighter gauge steel. Lastly it is easier to control with a welder as compared to a true steel wire and will bond/fit into tighter areas.
There are many advantages to using the aluminum welding method. One of them is that you can use a true continuous run repeat. Unlike a steel wire where you must stop and start over or else you will have a “hitch” in the weld. With the true spray transfer method you don’t have to worry about that. Another great thing is that you can use thinner gauges of steel. A true MIG welder would not be able to bond and fit into the tightest of places.
Another benefit to using the mig welding aluminum electrode wire is that it produces a smoother, better arc. The use of a constant current supply increases the energy that is produced. This means that you get a better, brighter weld and it will last longer. Most people will agree that a better weld is one that is very consistent.
One final benefit to using the aluminum tig weld is that there is a much smaller chance of injury if the torch is not held properly. Most workers that weld with a MIG torch will hold the torch much differently than a true gas torch. You have to remember that even with constant current and a tungsten electrode there is still a risk of overheating. If you hold the torch too long, it will cause the weld to come apart at which time you have to re-start your work piece welding process. With the mig weld aluminum torch you will never need to restart your welding process.
These are just a few of the many advantages of using the aluminum mig welding electrodes over a traditional tig weld. They can bond harder and thicker than a traditional tig weld and they require less maintenance. They are also much safer and easier to use than traditional tig weld electrodes.