Questions You Should Know about Mig Welding Wire

Welding aluminum

Aluminum in its pure form is a relatively soft metal that has many uses, but which requires the addition of an alloy or alloys to increase its strength and to add other qualities suitable for different applications. Common alloys are: copper, magnesium, silicon, manganese and zinc. They are identified by their series numbers:

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• Wrought Series Alloy groups
• 1xxx 99% minimum aluminum purity
• 2xxx copper
• 3xxx manganese
• 4xxx silicon
• 5xxx magnesium
• 6xxx magnesium-silicon
• 7xxx zinc
• 8xxx other
• 5xxx magnesium
• 6xxx magnesium-silicon
• 7xxx zinc
• 8xxx other

Aluminum, especially thin-gauge aluminum, presents some unique welding challenges. For many, GTAW is the preferred process, but GMAW offers some obvious benefits: higher deposition rates, less operator training and higher productivity. With these benefits come a few challenges, namely wire feeding and selecting the right type of filler metal and equipment. These challenges can be easily met, however, by knowing the answers to some common questions.

Frequently asked questions 

While filler metal for steel is typically chosen by matching the tensile strengths, strength is only one of the considerations when choosing an aluminum filler metal. Typically, there are several different aluminum filler metals that would be acceptable to use when welding aluminum base materials. In choosing a filler metal, consider:

-Base metal composition
-Ease of welding
-Joint design
-Dilution (when the filler wire and base metal combine in the weld puddle to create a different chemical make up in the weld)
-Strength of the weld
-Hot cracking sensitivity
-Ductility
-Corrosion in service
-Color matching, if the material is anodized
-Elevated service temperature (150-350 Fahrenheit)

Different filler metals address these considerations to varying degrees. In general, if strength is the primary consideration, the filler metal should closely match the base metal in tensile, yield and ductility.

Most consumable manufacturers, as well as the American Welding Society (AWS), offer information listing the relative values of these considerations of their filler metals for each base alloy. Always make sure to use an aluminum filler metal selection chart to address the weld properties listed above.

Traditionally, welders have relied on AWS and wires, as they can be used with the most widely used aluminum alloy base metals. Hobart, however, offers an alternative to filler metals to increase strength and quality. The MaxalMig®  aluminum wire offers approximately 20% higher tensile strength and doesn’t rely on diluting the aluminum base material to gain strength. This feature often allows welders to make smaller, single-pass welds and still get reliable strength. It also helps minimize the risk of distortion since heat input is lower. 

Aluminum as a filler metal has the same oxidation problems as all aluminum. When left open, either on the shelf or installed on the welder, aluminum filler wire will oxidize, which can lead to an erratic arc. The oxidation adds resistance, can produce smut and can change the wire’s ability to feed smoothly. Many operators have spent a great deal of time adjusting tension settings, changing contact tips or checking the shielding gas trying to fix the problem when it was the oxidized wire that was at fault.

Because of its low columnar strength, feeding aluminum wire has been likened to pushing a wet noodle through a straw. Birdnesting, or the tangling of the wire between the drive roll and the liner, is a common, time-consuming and costly problem. Clearing it requires the operator to stop welding, cut the wire, discard the wire in the gun and re-feed new wire through the liner. It also may require cleaning or changing the contact tip because of the burnback caused when the wire stops feeding.

There are several ways to feed aluminum wire: Push only, spool gun, push-pull system and continuous feed push-only system.

Push only: Feeding aluminum wire through a push-only system can be difficult, but it can be done on a limited basis. It requires u-groove drive rolls to provide more surface contact with the wire, adequate drive-roll pressure and the ability to keep the gun cable straight. Any resistance in the line will likely cause the wire to misfeed. Thicker wire, such as 1/16 inch, may be fed consistently in a push-feed system. But for thinner gauges, such as .030 inch, push feeding is not very dependable.

Spool gun: Welding aluminum with a spool gun, such as the Spoolmate™ or Spoolmatic® series of guns, eliminates the possibility of birdnesting by putting a 4-inch (1-pound) spool on the gun, so the wire only feeds a few inches. Spool guns can accommodate aluminum wire diameters from .023 to 1/16 inch and allow the operator to use longer cables (15-50 foot).

A spool gun needs to have the roll changed after every pound of wire is used, compared with the 16- or 22-pound spool on a push-pull system. In tight spaces, the spool may limit access, requiring the operator to use a longer stickout. If the operator is using several pounds of aluminum per day, the few minutes needed to change spools can add up. Also, the chance of burnback exists when the end of a spool is reached, so many operators stop when a few turns are left on the spool.

Push-pull gun: With a push-pull gun, a motor in the gun pulls the wire through the liner, while the motor in the welder or feeder control becomes an assist motor. By maintaining consistent tension on the wire, the push-pull system helps eliminate birdnesting. It is more ergonomic than the spool gun since the weight of the spool is not in the operator’s hands.

Also, the spool needs to be changed less often than on a spool gun and allows the purchase of larger spools. A push-pull gun also allows cables up to 50 feet long. The only disadvantage to push-pull systems is their relatively higher price tag, but the increased productivity and the financial advantage of buying larger spools usually provide a quick return on investment. When you compare the cost of 16 1-pound spools of .035-inch aluminum filler wire with one 16-pound spool of the same diameter wire, plus the time to change 16 spools versus one spool, you’ll see that for high-volume use, a push-pull system makes financial sense. 

A welding distributor, picked at random, lists a price for a 1-pound spool of .035-inch aluminum wire as $11.46. A 16-pound roll lists for $170.24, which works out to a difference of $0.82 per pound. Now, add the time for 16 spool changes (and possibly burnbacks) for the spool gun as compared with one change for the larger spool. At five minutes to change a spool, that’s 80 minutes of extra time for each 16 pounds of filler wire used.

Continuous-feed push system: This is a relatively new addition to the field. This type of system uses a special drive system that maintains continuous contact with the wire and eliminates the possibility of birdnesting since there is no gap between the drive rolls and the liner. While it is limited to pushing the wire 15 feet, the gun is lighter than either the spool gun or the push-pull gun and requires no additional maintenance.

Check out this article for more MIG welding aluminum best practices.

Does MIG welding require gas?

MIG welding typically requires gas to shield the weld from atmospheric contamination. The gas used is typically a mixture of argon and carbon dioxide or argon and helium. This gas flows through the welding gun and forms a shield around the weld puddle, protecting it from the oxygen, nitrogen, and other elements in the air that can cause defects in the weld.

MIG welding with gas is also known as gas metal arc welding (GMAW). There is a variant of MIG welding called flux-cored arc welding (FCAW), which uses a hollow wire filled with flux instead of gas for shielding. This process is useful in outdoor and windy conditions where the gas shield can be disrupted. However, FCAW has some disadvantages compared to GMAW such as higher smoke and spatter, and it may not produce as clean of a weld.

What is a MIG welder good for?

1. Welding thin or thick metal: MIG welding can be used to weld a variety of thicknesses of metal, making it suitable for welding everything from thin sheet metal to heavy structural steel.

2. Joining different metals: MIG welding can be used to join different metals, including aluminum, stainless steel, and mild steel. ArcCaptain MIG200 specializes in offering aluminum welders designed specifically for working with aluminum materials.

3. High production welding: MIG welding is a fast welding process that can be used to weld continuously, making it a good choice for high production welding applications.

4. DIY and home use: Arccaptain MIG200 welding is relatively easy to learn and can be used for a variety of DIY and home welding projects, such as repairing metal gates, fences, and furniture.

What is a good entry level MIG welder?

1. ARCCAPTAIN MIG130 Best 3 in 1 110V Portable: Ideal for beginners and DIY enthusiasts, this cost-effective, small-sized 3-in-1 machine enables flux core welding without gas cylinders, offering the versatility to work with stainless steel and expand your DIY capabilities.

2. Lincoln Electric K-1 Handy MIG Welder: This compact welder is great for small welding projects and is easy to use for beginners.

3. Hobart Handler 140 MIG Welder: This is a versatile and reliable welder that is suitable for welding a range of materials and thicknesses.

4. Forney Easy Weld 261 MIG Welder: This lightweight and portable welder is perfect for DIY enthusiasts and hobbyists who need a simple and affordable MIG welder.

5. Lotos MIG140 140 Amp MIG Welder: This welder is easy to set up and use and comes with a range of accessories, making it a great value for beginners.

6. Eastwood MIG 135 Welder: This welder is ideal for welding thin to medium thickness metals and is great for DIY projects and automotive repairs.

When selecting an entry-level MIG welder, it is important to consider your needs, budget, and the types of materials you will be welding. It is also important to choose a reputable brand and look for a welder that comes with a warranty and good customer support. 

Checkout ArcCaptain best beginner MIG welder, it's easy to use and perfect for those just starting out. And  If you're seeking a welder that combines convenience with power, the MIG welder 110V is the perfect choice for its portability.

What can a 100 amp MIG welder weld?

A 100 amp MIG welder can weld mild steel, stainless steel, and aluminum, but the thickness of the material that can be welded will be limited. Generally, a 100 amp MIG welder can weld mild steel up to 1/8 inch  thick, stainless steel up to 3/32 inch thick, and aluminum up to 1/8 inch  thick.

It is important to note that the maximum thickness of material that a MIG welder can weld also depends on the type of wire used, the shielding gas, and other factors. Additionally, the operator's skill level and technique can also impact the quality and strength of the weld.

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If you need to weld thicker material, you may need to consider a more powerful MIG welder or a different welding process such as TIG or stick welding. It is always important to consult the manufacturer's recommendations and guidelines for the specific MIG welder model and application.

Which is the best MIG welder to buy?

The best MIG welder for you will depend on your specific needs and budget. Some of the top-rated MIG welders on the market include:

1. ARCCAPTAIN MIG200 Multi Process MIG Welder: This is a user-friendly dual voltage multi-process MIG welder, perfect for DIY, fabrication, repair projects, and it is a good welder for aluminum materials. Its versatile design makes it a great investment for anyone seeking a dependable and efficient MIG welder.

2. Lincoln Electric PowerMIG 210 MP: This versatile welder is great for both hobbyists and professionals and is capable of welding a wide range of materials.

3. Miller Multimatic 215: This high-performance welder is ideal for welding aluminum and other materials and is also easy to use for beginners.

4. Hobart Handler 210 MVP: This welder is highly portable and can be used with both 115V and 230V power sources, making it a great choice for those who need to weld in multiple locations.

5. Everlast PowerMIG 140E: This welder is affordable and easy to use, making it a great option for DIY enthusiasts and hobbyists.

6. ESAB Rebel EMP 215ic: This welder is highly versatile and can be used for MIG, TIG, and stick welding, making it a great choice for those who need to weld a range of materials.

When selecting a MIG welder, it is important to consider factors such as the materials you will be welding, the thickness of the material, and the size of the project. It is also important to choose a reputable brand and look for inexpensive welding machines that comes with a warranty and good customer support.

What materials can be welded using a MIG welder?

MIG welders can be used to weld various materials, including steel, stainless steel, aluminum, and some other metals.

How do I select the right size and type of MIG welding wire for my project

The size and type of MIG welding wire depend on the thickness and type of metal being welded. The welding wire size is usually chosen based on the metal thickness, and the type of wire is chosen based on the metal being welded.

What type of gas is used with a MIG welder and why is it necessary?

A shielding gas is used with a MIG welder to protect the weld from the atmosphere, preventing oxidation and contamination. The type of gas used depends on the metal being welded and the welding wire used.

What are the advantages and disadvantages of using a MIG welder compared to other welding processes?

The advantages of MIG welding include high welding speeds, low levels of spatter, and ease of use. The disadvantages include limited penetration and the need for a clean, non-rusty surface for welding.

How do I set up my MIG welder and adjust the settings for different welding tasks? 

The MIG welder should be set up according to the manufacturer's instructions, and the settings adjusted based on the type and thickness of the metal being welded.

What safety precautions should I take when using a MIG welder?

Safety precautions when using a MIG welder include wearing protective clothing, using a welding helmet, ensuring proper ventilation, and using appropriate welding techniques.

How do I troubleshoot common problems with my MIG welder?

Common problems with MIG welders include wire feeding issues, poor weld quality, and gas leaks. Troubleshooting involves identifying the root cause of the problem and addressing it appropriately.

What maintenance tasks should I perform to keep my MIG welder running smoothly? Answer: Maintenance tasks for MIG welders include regular cleaning, replacing worn parts, and keeping the welder properly lubricated. 

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