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  1. #1
    Join Date
    Aug 2007
    Location
    Vancouver BC Canada
    Posts
    605

    Default aluminum and spatter

    Hi Guys, (and Gals)

    I have a 30A spool gun on my 250.
    I will be welding 1/8th to 3/16th and id like to know what i can do to minimze spatter. I seem to be getting lots of carbon and white residue on my welds as well as a brilliant spark show. The weld arc doesnt seem to be hissing as it should, its more a of a crackle/hiss.

    parameters i am roughly following to date include 30 degree tip angle and a push path as recommended for mig'n AL.

    material is all 5000 (5086) series with 5356 0.030 filler wire.

    Oh yeah and I read in another post somewhere about holding the trigger and turning on the main power on the mm250. I didnt get what was being described so i tried it. What i found was that the numbers changed in the dispaly and the gun fed at a differerent rate. Still confused. Too much on my little mind. would someone care to explain what i did? thanks.

    Thanks Guys, any info or suggestions would be well received.

    Rich.
    Last edited by SignWave; 12-03-2007 at 01:37 PM.
    Will it weld? I loooove electricity!

    Miller 251/30A spool
    Syncro200
    Spectrum 625
    O/A
    Precix 5x10 CNC Router12"Z
    Standard modern lathe
    Cheap Chinese mill that does the trick... sort of...
    horizontal 7x12 bandsaw
    Roland XC540 PRO III
    54" laminator
    hammer and screwdriver (most used)
    little dog
    pooper scooper (2nd most used...)

  2. #2
    Join Date
    Nov 2006
    Location
    Lake of the Ozarks MO
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    3,588

    Default

    Sounds like the gas is not flowing thru

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  3. #3
    Join Date
    Aug 2007
    Location
    Vancouver BC Canada
    Posts
    605

    Default

    lotsa gas. 15-20cfh 100% Argon.
    Will it weld? I loooove electricity!

    Miller 251/30A spool
    Syncro200
    Spectrum 625
    O/A
    Precix 5x10 CNC Router12"Z
    Standard modern lathe
    Cheap Chinese mill that does the trick... sort of...
    horizontal 7x12 bandsaw
    Roland XC540 PRO III
    54" laminator
    hammer and screwdriver (most used)
    little dog
    pooper scooper (2nd most used...)

  4. #4
    Join Date
    Nov 2006
    Location
    Lake of the Ozarks MO
    Posts
    3,588

    Default

    .030 sounds sorta small from my exp. Man I bet you gotta have the wire speed litterally screaming.
    I always use .064 and anything too thin for that gets tigged.
    I believe I would crank the gas WWAAYY higher and see what happens as I generally use more flow when migging AL.
    Also more stickout than you are used to.
    I would think .030 would be a birdnesting nitemare but prolly would spray at a lower amp. Been meaning to try it on mine but .064 works so good for me in 11 yrs I still ain't tryed it.
    Come to think of it everywhere I've worked used the big wire in the 30A.
    Doesn't mean it won't work fine tho.

    www.facebook.com/outbackaluminumwelding
    Miller Dynasty 700...OH YEA BABY!!
    MM 350P...PULSE SPRAYIN' MONSTER
    Miller Dynasty 280 with AC independent expansion card
    Miller Dynasty 200 DX "Blue Lightning"

    Miller Bobcat 225 NT (what I began my present Biz with!)
    Miller 30-A Spoolgun
    Miller WC-115-A
    Miller Spectrum 300
    Miller 225 Thunderbolt (my first machine bought new 1980)
    Miller Digital Elite Titanium 9400

  5. #5
    Join Date
    Aug 2007
    Location
    Vancouver BC Canada
    Posts
    605

    Default Im sorry

    Sorry Fusion,
    I mistakenly said 030 when it was 035. not much of a diff but a diff none the less.

    is spatter common when mig'n AL?
    Will it weld? I loooove electricity!

    Miller 251/30A spool
    Syncro200
    Spectrum 625
    O/A
    Precix 5x10 CNC Router12"Z
    Standard modern lathe
    Cheap Chinese mill that does the trick... sort of...
    horizontal 7x12 bandsaw
    Roland XC540 PRO III
    54" laminator
    hammer and screwdriver (most used)
    little dog
    pooper scooper (2nd most used...)

  6. #6
    Join Date
    Nov 2006
    Location
    Tucson, AZ
    Posts
    37

    Default

    is the aluminum clean? we also do 1/8th" to 1/4" but we use 3/64" wire

  7. #7
    Join Date
    Nov 2006
    Location
    Lake of the Ozarks MO
    Posts
    3,588

    Default

    Quote Originally Posted by srl_welder View Post
    is the aluminum clean? we also do 1/8th" to 1/4" but we use 3/64" wire

    Now I'm doing it
    I knew there was a 64 in there somewhere...what decimal is that?
    Anyhow it runs GOOD.
    Yea it spatters but not horrible...I do put my leathers on tho

    www.facebook.com/outbackaluminumwelding
    Miller Dynasty 700...OH YEA BABY!!
    MM 350P...PULSE SPRAYIN' MONSTER
    Miller Dynasty 280 with AC independent expansion card
    Miller Dynasty 200 DX "Blue Lightning"

    Miller Bobcat 225 NT (what I began my present Biz with!)
    Miller 30-A Spoolgun
    Miller WC-115-A
    Miller Spectrum 300
    Miller 225 Thunderbolt (my first machine bought new 1980)
    Miller Digital Elite Titanium 9400

  8. #8
    Join Date
    May 2007
    Location
    Apache junction, AZ
    Posts
    16

    Default

    there is no way to stop the spatter, its like a package deal. but it should easily be removed by running a putty knife or chisel over it. Also more argon is worse for aluminum than too little. i personally think 15-20cfm is too high. i was tought, and learned from experience that 10-15 is quite enough, and also produces a nicer looking weld. Another variable could be the type of brush you are using to prepare it. If you are using a carbon steel brush it is contaminating it. you always want to use a clean stainless steel brush that was never used for anything but aluminum. even using an zirconia flap wheel, or aluminum oxide wheel could contaminate the aluminum bad enought to give you a weld that looks like bird poo. hopes this helps.

  9. #9
    Join Date
    Nov 2006
    Location
    Lake of the Ozarks MO
    Posts
    3,588

    Default

    I've found just about the oppposite....Spoolgun will run on the nastiest used crap out there in situations you couldn't begin to get a decent tig weld as long as the gas is high enuff.
    If I can barely get to something and cleaning is immpossible I get out the spoolgun.
    Also found the gas flows good at first and then drops off so a good flowing regulator is needed as well.
    I have not welded on 5086 tho...more of a saltwater thing..and super hard like unbendable(H100?). what is it?
    Last edited by FusionKing; 12-03-2007 at 10:30 PM.

    www.facebook.com/outbackaluminumwelding
    Miller Dynasty 700...OH YEA BABY!!
    MM 350P...PULSE SPRAYIN' MONSTER
    Miller Dynasty 280 with AC independent expansion card
    Miller Dynasty 200 DX "Blue Lightning"

    Miller Bobcat 225 NT (what I began my present Biz with!)
    Miller 30-A Spoolgun
    Miller WC-115-A
    Miller Spectrum 300
    Miller 225 Thunderbolt (my first machine bought new 1980)
    Miller Digital Elite Titanium 9400

  10. #10
    Join Date
    Aug 2007
    Location
    Vancouver BC Canada
    Posts
    605

    Default

    I use nothing but a stainless brush. I have two that are dedicated to AL.
    I even change gloves when Im welding or grinding.


    Fusion, I kow what you mean by:
    "when nothing else works, I reach for the 30A."

    All of the AL I am using (for the most part) is bright shiny clean. If it isnt it gets the once over with the wire brush< bu teven if i dont clean it, I have noticed that this really hasnt been an issue.

    WItht the tig, I just crank up the cleaning action and it fuses well.

    anyway, I guess i'll try lowering the cfh and see what happens. I'll be welding some more pieces in today so. I'll get back to you all.

    Thanks for the replies and suggestions so far.

    Rich.
    Attached Images Attached Images
    Will it weld? I loooove electricity!

    Miller 251/30A spool
    Syncro200
    Spectrum 625
    O/A
    Precix 5x10 CNC Router12"Z
    Standard modern lathe
    Cheap Chinese mill that does the trick... sort of...
    horizontal 7x12 bandsaw
    Roland XC540 PRO III
    54" laminator
    hammer and screwdriver (most used)
    little dog
    pooper scooper (2nd most used...)

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