Miller Electric

Aluminum Systems

Home » Products » Aluminum Systems

Aluminum Systems

The structural and aesthetic benefits of aluminum continue to make it one of the most specified materials in the industry today. The challenges — whether in transportation, shipbuilding, fabrication, manufacturing or home/hobby — are similar: distortion, cleanliness, quality and speed. Arming yourself with the right equipment and consumables will make the job easier.

Brochure

Ask The Aluminum Expert

Your total welding solutions provider

Miller is committed to providing a total aluminum welding solution for your business. You can count on our easy-to-use equipment to improve quality and increase your productivity, profitability, and peace of mind.

Aluminum MIG System
Aluminum TIG System
 

Military, pleasure and commercial ships

Aluminum is increasingly specified on ships of all sizes because it makes them lighter without sacrificing strength and functionality. This makes them faster, saves on fuel and provides ships with the corrosion resistance benefits of aluminum - but it also presents numerous welding challenges. Whether your operation requires fast production speeds (hull construction) or intricate detail work (aluminum pipe and fittings), Miller has the right solution.

AlumaFeed® Synergic MIG System Miller recommends Hobart

AlumaFeed® Synergic MIG System

  • AlumaPower 350 MPa power source
  • XR-AlumaFeed® wire feeder
  • XR-Aluma-Pro gun

System features and benefits:

  • Portable wire feeder ideal for going up stairs, through portholes or mounting on booms to reach every corner of the work area.
  • Achieve the stacked dime appearance of TIG with the production speeds of MIG thanks to Miller's Profile Pulse technology.
  • Easy to use/reduces burn through and distortion: One-knob synergic welding control sets the correct Pulse parameters based on the wire feed speed set by the operator; allows the operator to adjust to varying joint profiles or material thicknesses.
  • Ensure proper fusion at the beginning of the weld, thanks to Hot Start technology.
  • Long, linear welds easily performed, thanks to interface with semi- automatic welding systems/positioners.
  • Further simplify operation with built-in Pulsed MIG programs designed for most commonly used aluminum alloys.

Learn More

Dynasty® 350 TIG System

Dynasty® 350 TIG System

  • Dynasty 350 power source

System features and benefits:

  • Capable of welding a wide variety of thicknesses and types of aluminum, ranging from thin sheet to pipe.
  • Ensures an excellent finish through reduced spatter, cleanup and distortion.
  • Easily join thick materials to thin materials while ensuring proper penetration and not blowing through the thin section.
  • Joining hangers and brackets to the superstructure is simplified with advanced AC TIG controls that ensure optimum quality and aesthetics with a smooth finish.
  • Address changing geometries, varying joint fit-ups and inconsistencies with remote amperage control.

Learn More

 

Semi-truck trailers, carriers and emergency vehicles

Welding for the transportation industry requires strength and quality as these components take a heavy beating on the road. There's also a wide variety of assemblies and production methods that require operational flexibility, including switching from aluminum to other metals. That's why Miller offers MIG and TIG systems that ensure the functionality and appearance of the vehicles on our highways.

Invision™ MPa Plus MIG System Miller recommends Hobart

Invision MPa Plus MIG System

  • Invision 352 MPa Plus power source
  • D-74 MPa Plus dual wire feeder
  • XR-Aluma-Pro Plus gun

System features and benefits:

  • Increase wire feeding consistency to improve productivity with advanced push-pull wire feeding technology.
  • Achieve the "stacked dime" appearance of a TIG weld and MIG production speeds with Miller's Profile Pulse technology.
  • Can reduce or eliminate porosity and inclusions in the weld with easy-to- use start and crater functions.
  • Quickly switch from aluminum to other alloys with a dual wire feeder.
  • Easy to use/prevent burn through and distortion: one-knob synergic welding control sets the correct Pulse parameters based on the wire feed speed set by the operator; allows the operator to adjust to varying joint profiles or material thicknesses.
  • Extend welding range for large trailers and assemblies with Miller's Alumination technology for reliable, dependable and consistent wire feeding over longer distances.

Learn More

Dynasty® 350 TIG System

Dynasty® 350 TIG System

  • Dynasty 350 power source

System features and benefits:

  • TIG inverter benefits include increased productivity, improved quality, energy efficiency and portability.
  • Deposit filler metal in a very controlled manner to meet superior weld quality and aesthetics standards.
  • Ensure fit-up and alignment of bracket and tubing assemblies by eliminating spatter, arc wandering and over-welding.
  • Ideal for fabricating leak-free water and fuel tanks/fittings from aluminum sheets and tubing.
  • Advanced AC TIG controls produce defect-free welds, improve cleaning action, reduce etching and control heat input to minimize distortion and maintain critical dimensions.

Learn More

 

Boats, RVs, utility trailers, truck accessories, signs and lawn furniture

Projects in this market vary considerably, which results in the critical need for versatility in welding equipment. Superior strength-to-weight ratios, corrosion resistance, sturdy wall joints and aesthetic welds are essential in these applications. Miller aluminum systems offer the flexibility and mobility you need for everything from subassembly to the final weld.

Millermatic® 350P MIG System Miller recommends Hobart

Millermatic® 350P Aluminum MIG System

  • Millermatic 350P Aluminum power source
  • OR XR-Aluma-Pro Lite gun
  • XR-Aluma-Pro™ gun

System features and benefits:

  • Compatible with most Miller Push-Pull guns for consistent wire feeding; expands work envelope up to 35 feet without moving the power source.
  • True torque feed motor push-pull design provides continuous push force to the wire while the gun motor controls the speed at the gun. The motors work together to provide accurate and positive wire feed speed without wire shaving or deformation.
  • Pulsed MIG reduces heat input, resulting in less warping, distortion and spatter — increasing productivity and reducing rework. Ideal for thin gauge materials.
  • Synergic MIG provides communication between power source, feeder and gun. As wire speed increases/decreases, the arc voltage also increases/decreases to maintain a constant welding arc.
  • Easy to use: One-knob synergic welding control sets the correct Pulse parameters based on the wire feed speed set by the operator; allows the operator to adjust to varying joint profiles or material thicknesses.
  • Produces high deposition rates and fast weld speeds for long joints and production welding.
  • Compact, all-in-one welding system with running gear makes it easy to move around the weld cell.

Learn More

Dynasty® 350 TIG System

Dynasty® 350 TIG System

  • Dynasty 350 TIG Runner

System features and benefits:

  • TIG inverter benefits include increased productivity, improved quality, energy efficiency and portability
  • Capable of welding a wide range of material, including thin gauge to 5/8" thick aluminum.
  • Precise arc and directional control for accurate weld sizing and placement.
  • Reduced distortion and burn-through on thin and delicate parts.
  • Produces aesthetically pleasing welds with no sparks, spatter or slag, reducing cleanup and finishing time.
  • Advanced AC TIG controls allow for welding anodized aluminum in a single pass - a major increase in productivity.
  • Remote amperage control lets you compensate for changing geometries, varying joint fit-ups, and inconsistencies — without sacrificing weld integrity.

Learn More

 

Suspension, frames, body, radiators, drive shafts and wheels

Fabrication for the automotive market requires repeatable, high-quality welds for all subassemblies and assemblies. Available for MIG and TIG, Miller Automation features an integrated welding power supply inside the robot controller that delivers precise arc starts and stops, reduces the amount of rework and secondary operations and ultimately increases productivity.

TAWERS MIG Automation System Miller recommends Hobart

TAWERS MIG Automation System

System features and benefits:

  • Lift start results in precise arc ignition, eliminating costly wire burn-back that destroys the tip.
  • Retract start reverses the wire the moment it touches the part, avoiding bird nesting.
  • As the robot transitions from thin to thick sections, spiral weaving adjusts the amount of heat input for better weld control.
  • Robot controls let the weld ramp up and down without moving the robot, providing either a back-stepped crater or the perfect button at the end.
  • Synchronized low pulse produces an ideal bead appearance.
  • Servo Push-Pull feeding systems on robots provide the precision and performance necessary for successful aluminum welding.
 

Hobbies, metal object fabrication and home repairs

It is now easier than ever for welders of all skill levels to weld aluminum. Whether you use your welding equipment to repair things, create art, or support your motorsports habit, Miller offers easy-to-use MIG and TIG machines that deliver the flexibility, portability and professional results you want at an affordable price - all while simplifying controls and operation.

Millermatic® 211 Auto-Set™ with MVP™ MIG System Miller recommends Hobart

Millermatic® 211 Auto-Set with MVP MIG System

  • Millermatic 211 power source
  • Spoolmate 100 spool gun

System features and benefits:

  • Great welding versatility - capable of welding 24 ga. to 3/8” aluminum and steel.
  • Spool gun options for improved aluminum feeding and extending the work envelope.
  • Auto-Set makes setup easy - MVP technology allows you to use either 115 V or 230 V power simply by changing the plug (230 V power recommended when welding aluminum).
  • Compact and portable for easy maneuvering around shop.

Learn More

Diversion™ 180 TIG System

Diversion 180 TIG System

  • Diversion 180 power source

System features and benefits:

  • Great welding versatility - capable of welding up to 3/16" thick aluminum and steel.
  • Easy to use - selecting material type and thickness sets the parameters, further simplifying the TIG process.
  • Works no matter what your input power is; as MVP technology allows for operation on 115 V or 230 V power - simply by changing the plug.
  • Arc inconsistencies from input power fluctuations are eliminated with Miller's Auto-Line technology.
  • Extreme portability - weighs only 50 lb. and has two convenient cord- wrap handles.

Learn More

 

Your source for quality filler metal

HobartHaving the right aluminum filler metal is the best complement to a dedicated aluminum welding system. From helping to improve weld quality to increasing productivity and reducing costs, quality aluminum filler metals can mean the difference between downtime for rework and getting the job done right the first time — every time. Hobart® aluminum wires and cut lengths offer the consistency and the performance you need.

Hobart® Aluminum Filler Metals:

  • MaxalMig wire
  • MaxalTig cut lengths

Features and benefits:

  • Outstanding feedability to minimize issues with birdnesting and extend consumable life
  • Superior arc stability and arc starts for quality welds
  • Minimal burnback to reduce downtime and costs for contact tip changeover
  • X-ray weld quality for critical applications
  • Less need for oscillation to help reduce operator fatigue
  • Consistent wire diameters for consistent results
  • Extreme cleanliness that exceeds the AWS porosity standard and reduces rework