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  1. #1
    Join Date
    Feb 2008
    Location
    Milford, Ohio
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    Default Welding Aluminum - Miller Maxstar

    Is there any way aluminun can be welded with a Maxstar 200 DX?

  2. #2
    Join Date
    Aug 2006
    Location
    near rochester NY
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    9,881

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    strait helium and make shore its very clean.
    what size are you planing on working with?
    what is you experience level ??
    the Dyn200DX would be much essayer to weld aluminum with. AC allows for cleaning wile welding.
    if you have to use DC, it can be done. maybe some of the pro's will jump in and help out with the details. i have never tried it, i use AC with good results. but have heard of DC being used.
    thanks for the help
    ......or..........
    hope i helped

    feel free to shoot me an e-mail direct i have time to chat. james@newyorkmetalart.com
    summer is here, plant a tree. if you don't have space or time to plant one sponsor some one else to plant one for you. a tree is an investment in our planet, help it out.
    JAMES

  3. #3
    Join Date
    Dec 2007
    Location
    National City CA
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    1,086

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    DC and aluminum is for Mig machines.
    It can be done but it's more of filling in holes and globing material on then welding. Very little control over what can barley be called a bead.
    Sorry but you need AC.
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  4. #4
    Join Date
    Nov 2006
    Location
    London
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    129

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    Good quality welds can be made with helium and DCEN bit the process is only really suitable for thick sections

    Helium produces a 'hotter' arc (higher voltages than argon) making it a deep penetrating and fast process. Pre cleaning is more important (than with AC) and even then the weld pool is poorly defined. There will be some 'soot' on the surface of the weld

    Factor in the increased costs associated with He (as well as being expensive, higher flow rates are required) and it's rarely practical for most people. Arc starting is also more difficult due to the higher ionization voltage of He

    GMAW aluminium welds are done with DCEP, plenty of cathodic 'cleaning' action. DCEP with TIG puts far more heat into the tungsten- possible for very thin sections with a large tungsten but again not practical

  5. #5
    Join Date
    Aug 2006
    Location
    near rochester NY
    Posts
    9,881

    Default

    he is working with 3/16" material. not the best option but with skill it can be done. again not the best choice, but if its the only option. grab up some stock and put in some practice time before risking the project. i would look at getting a good cleaning or etching solutions to aid the process.

    i wish hawk was still here he used DC a lot, not by need but by choice. high skill levels were definitely in use.
    thanks for the help
    ......or..........
    hope i helped

    feel free to shoot me an e-mail direct i have time to chat. james@newyorkmetalart.com
    summer is here, plant a tree. if you don't have space or time to plant one sponsor some one else to plant one for you. a tree is an investment in our planet, help it out.
    JAMES

  6. #6
    Join Date
    Apr 2008
    Location
    Carlsbad, CA
    Posts
    27

    Default

    Fred,
    I think Cannondale uses DC to weld their bicycle frames. They weld some insanly thin tubes. The welds look similar to a fillet brazed joint, very concaved, wide and unrippled. I think larger tungstons are needed, due to the polarity used. I don't know what sheilding gas they use. The frames are heat treated after welding.
    Russ

  7. #7
    Join Date
    Dec 2013
    Location
    At the epicenter of the Green Mountain Range in VT
    Posts
    276

    Default

    Quote Originally Posted by Fred Williams View Post
    Is there any way aluminun can be welded with a Maxstar 200 DX?
    As an experiment, with a 1/8 pure tungsten on 1/4" alum. running a bead using a dialarc HF It wasn't as bad as I expected. The oxide stays where it is, the filler flows beneath it. It doesn't make a pretty weld.

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