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Miller Electric OM-234 016D manual Gmaw MIG Aluminum Welding Hints, Before You Start Welding

Models: OM-234 016D

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5-5. GMAW (MIG) Aluminum Welding Hints

Here are several hints to help you be more successful with your new aluminum feed system.

MIG welding aluminum requires different techniques than MIG welding mild steel.

A. Before You Start Welding

SThe removal of lubricants from the aluminum base material may be necessary. Consult with your local welding distributor for their recommendation on aluminum cleaners.

SOxide removal should be done after degreasing. This should be done with a stainless steel wire brush. This can be done with a hand wire brush or with a cup wire brush. If a power wire brush is used, keep the RPM’s and pressures low to reduce smearing the surface of the material, which could entrap oxides and impurities under the surface. Always use a wire brush that is used only on aluminum to keep from contaminating the base material.

SContact you local welding distributor or aluminum filler metal representative for recommendations on wire alloys that fit your application. Know the alloy of your base aluminum and what conditions the finished part will be subjected to. The two most readily available aluminum filler wires are ER4043 and ER5356.

B. Welding Techniques

SMake sure the welding power source is set up to weld DCEP (DC Electrode Positive).

SFor MIG welding aluminum you need to use a 10 to 15 degree push travel angle (tip and nozzle pointing in the direction of travel). See Figure 5-1.

Side View Of Gun Tip Angle

10°-15°10°-15°

Direction Of Welding
Forehand (Push)	Backhand (Drag)
Technique	Technique

Figure 5-1. Gun Tip Angle

SPulling or using a drag angle will produce porous, dirty welds due to a lack of gas coverage.

SThe reflective heat and weld puddle that is present when MIG welding aluminum is very hot. Holding the tip closer than 3/4 in. could lead to the wire burning back to the contact tip and other feeding problems.

SThe most common shielding gas for MIG welding aluminum is 100% argon. Flow rates of 20 to 30 CFH [cubic feet per hour (0.57 to 0.85 m3/hr)] are acceptable. C25 or argon CO2 shielding gases are not acceptable.

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Miller Electric OM-234 016D manual Gmaw MIG Aluminum Welding Hints, Before You Start Welding, Welding Techniques

Contents

OM-234 016D File Wire FeederProcesses DescriptionFrom Miller to You Table of Contents Page Arc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can cause severe burnsARC Rays can burn eyes and skin Fumes and Gases can be hazardousWelding can cause fire or explosion Flying Metal or Dirt can injure eyesFire or Explosion hazard Welding Wire can cause injuryFalling Unit can cause injury Moving Parts can cause injuryCalifornia Proposition 65 Warnings Principal Safety StandardsEMF Information About Implanted Medical DevicesUNE Décharge Électrique peut entraîner la mort Symboles utilisésLES Fumées ET LES GAZ peuvent être dangereux DES Pièces Chaudes peuvent provoquer des brûlures gravesLE Soudage peut provoquer un in cendie ou une explosion LES Bouteilles peuvent exploser si elles sont endommagées LE Bruit peut endommager l’ouïeRisque D’INCENDIE OU D’EXPLO LA Chute DE L’APPAREIL peut blesserLES Fils DE Soudage peuvent provoquer des blessures Proposition californienne 65 AvertissementsLE Soudage À L’ARC risque de provoquer des interférences Information EMF Principales normes de sécuritéEn ce qui concerne les implants médicaux OM-234 016 Removing MIG Gun From Welding Power Source SpecificationsTurn Off unit, and disconnect input power Connecting Spool Gun To Millermatic 140/180 ModelsOperation Polarity Changeover Terminal Block Close door Connecting Spool Gun To Millermatic 140/180Incorrect Connecting Spool Gun To Millermatic Passport PlusCorrect Connecting Spool Gun To Renegade Installing Wire Spool And Threading Welding Wire Spool Gun Operation On Millermatic 140/180 Models Controls For Millermatic 140/180 ModelsExample .030 diameter wire, welding 18 ga. material Weld Parameter Chart For Millermatic 140 Model w/Auto−SetENumber on right Slash is Wire Refer to chart below to select Voltage and Wire Speed basedExample 4 Selecting Wire, Gas and Control Settings for Aluminum With optional Spool Gun. Order part no 035 0.9 mm 030 0.8 mm#220179 #202926 #220179225 229−E OM-234 016 Spool Gun Operation On Millermatic Passport Plus Model Controls For Millermatic Passport Plus ModelAr / 2.5% CO 0350.9 mm Min/15 Weld Parameter Chart For Millermatic Passport Plus Model115/230V 100 100 10/80 10/60 10/90230V 235557−ASpool Gun Operation On Renegade 180 Model Controls For Renegade 180 ModelAluminum 4043 Dcep 030 10/100 Weld Parameters For Renegade 180 Model035 10/90 Aluminum 4043 Dcep 030 10/75= Check = Change ~ = Clean = Replace Routine MaintenanceChanging Drive Rolls Turn Off power at welding power source firstChanging Push Roll Changing Lower Drive RollChanging Liner TroubleshootingBefore You Start Welding Gmaw MIG Aluminum Welding HintsWelding Techniques Direction Of WeldingGas Nozzle Contact Tip To Work Contact Tube Recessed 1/8 Common Problems/Troubleshooting− Electrical Diagrams Circuit Diagram For Millermatic 140/180 234 419-B − Parts List Optional Page Page Page Your distributor also gives ServiceSupport Miller Electric Mfg. Co To locate a Distributor or Service Agency visitFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s