Mig Welding thin (.063) aluminum tube...HELP

[Merc69]

After many years of not haveinto weld this thin stuff I have obligated myself to assist a friend.

This is .063 wall 1" square aluminum tube, short 1 inch welds. Production is the key so tig welding is out. This could be a long term project with multiple frames having to be made. They currently have an older Hobart Welder and an aftermarket spoolgun. While it works well I am having cold starts and alot of blow through on this thin stuff.

Options and opinions as to which way to turn with this. I have waisted way to much time on chasing holes and dressing up my mess. I have an XMT 304 at home...how well does the Miller add on pulse unit work with the spoolgun on stuff this thin? Or should I scrap that idea and look at a MM 350P?

HELP :confused: :confused:

[tigman250]

need more info, what is the application of the finished product? what wire are you using? what size? what grade material? this should be doable with a mig gun with the proper setup, but more info is needed.

Craig

[Scott V]

I have an XMT 304 at home...how well does the Miller add on pulse unit work with the spoolgun on stuff this thin?

It will get you there!!!

[Merc69]

Details:

The finished product is awning frames. Material is 1" X 1" X.063 - 6061. I believe they are supplying 4043 wire, .035 diameter.

Appearance is as important as structural.