Done MIG for years with steel. Just purchased a new 350P w/ aluminum Pro package for an extensive sculpture project I'm working on. Welding 3/8" round 6061 alloy with .035 4043 wire, 100% Argon-- new metal--prepping with SS wire brush. Suggested pulse-mig setting at wire speed of 650/arch length 50/arc control 25 just melts the **** out of the base metal and I can't control the weld even though I'm practically tack welding. I also keep getting black oxide residue. My current settings of 380 wire speed/ arch length 18 /arch control 40 is giving me better weld control but I still have problems. 1. getting splatter, 2. still getting black oxide, 3. welding wire to contact tip (ruined 2 tips today), 4. randomly arc/wire literally cuts into the base metal and melts sections of the base metal? I'm starting with a 1 second pre-flow and wire about 1/4" lead at the start of the weld. I've TIG welded aluminum fine in the past. This MIG process is kicking my butt. Any suggestions or recommendations would be greatly appreciated. I could post images of welds if that would help.
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Problem with 350P aluminum welding