January 22, 2022
  • January 22, 2022

What it’s like to work with MIG welding of aluminum

By on November 25, 2021 0

Different projects require different methods and tools, that way welding different materials requires you to choose the right tools to get the results you want. Working with aluminum is difficult due to its high conductivity and low melting point, if your arc is too strong, the metal will simply melt. While the oxidized film on the surface of aluminum has a different melting point than aluminum itself and is therefore difficult to work with even for experienced welders.

Aluminum is suitable for both MIG and TIG welding, the difference between the most suitable method is the thickness of the material, for thicker welding, MIG is recommended because it can get the job done faster, while for thinner aluminum, TIG is more suitable. In this article, we will look at MIG welding of aluminum.

While TIG welding is mainly used when working with aluminum, MIG welding is better suited for certain aluminum welding jobs. On larger projects, such as in an industrial environment when working with thicker materials, MIG welding is better suited due to the increased speed due to the simple operation.

On a MIG welding machine, you will find a spool that contains the wire used to create the weld pool. This strong wire is fed continuously through the welding gun, where the arc melts the wire, depositing it like a weld pool, which cools down to form the weld itself.

Now, again thanks to the simple operation, a MIG welder has the advantage of speed as a factor in your project. Its simple, one-handed operation allows for increased speed and productivity, while the welds themselves may lack aesthetics, this is still a great option if productivity is more important than quality.

Pulsed MIG welding

One of the most effective methods for welding thick and thin aluminum is pulse welding. Essentially, pulsed MIG welding works by controlling the electrical output of the welding machine using advanced control technologies. As the current pulses, the electrode melts as a controlled droplet, with each pulse forming a droplet.

Often referred to as synergistic control, this welding method is relatively easy to perform, even inexperienced welders can perform it. The advantages of pulsed MIG welding include:

  • Improved productivity – High deposit rates and less time spent training new hires
  • Consumable Savings – Pulsed MIG welding machines have a wider operating range because the low and high diameter range for the wire has been extended, which means you can use one wire size for most applications.
  • Improved weld quality – This method results in better overall weld quality because the arc is more stable, resulting in less spatter and less cleaning.
  • Heat Reduction – By providing controlled heat, pulse MIG welding results in less distortion, which is especially important when welding heat sensitive metals such as aluminum.

The right MIG welding machine

MIG welders suitable for aluminum generally have the following characteristics:

  • It should be designed with a spool gun that allows the use of a spool with wire, or one that offers a short Teflon jacket and wire feed system with a smooth U-shaped roll.
  • The duty cycle should reflect the environment you are working in, especially crucial if you are working in a hot environment.
  • Should have guards in place to prevent overheating, as MIG welding machines may overheat when used with aluminum.

If you are working on a larger project, MIG welding offers a productive and fast method of reliably welding thicker materials. While the cost is lower than TIG welding because the parts are easily replaceable and cheaper. Also being more profitable because you finish projects much faster.

There are major differences between MIG welding and TIG welding, especially when it comes to welding aluminum, the main difference is when welding thin aluminum sheet, in which case TIG welding holds the advantage.

In summary, MIG welding is your best option if:

  • Speed ​​and precision are essential.
  • High strength welds that require minimal cleaning and sanding are the goal.
  • Welding work is carried out indoors, since shielding gas is less effective outdoors.
  • One-handed operation is essential.
  • You need minimal faults because continuous operation decreases starts and stops.
  • The metals to be welded are thick, or so you can take great care not to burn the thinner materials.
  • You want to weld more parts in a short time, such as jobs involving heavy and continuous operations.

For general use, MIG welding is recommended due to its ease of use and versatility.

Visit our site, engweld.co.uk for more information and products related to MIG welding


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