Thicker Wires for Thin Aluminum?
Have You Tried Using Thicker Wires When Welding Thin Aluminum? In the “old” days we had no other choice when MIG welding aluminum but to weld at lower amperages and use .030 in. wire, otherwise we’d risk burn-through or our wire would “bird nest”. However, newer technology allows operators to control heat input and use thicker wire sizes, like 3/64 in. How is this possible? What’s the benefit? It’s possible to MIG weld aluminum with thicker wires because of pulsed MIG technology. A power source with pulsed MIG allows the wire to transfer across the arc at higher amps and then switch to lower amps so the puddle can cool and solidify. Therefore, the aluminum does not burn through. And, when using thicker wires you get increased column strength, the wire is stiffer, so it feeds easily and smoothly, without birds nesting. More importantly, at least to some, is that a thicker wire, like 3/64 in., costs less per pound than thinner wires. Are you concerned that if you switch from thinner to thicker wires for MIG welding aluminum that you will have burn throughs? If you answered yes, I challenge you to give it a try. Ask your distributor for a demonstration. Do you think the cost of upgrading to a pulsed MIG machine is cost prohibitive? Than consider the costs of more expensive wires, the cost of downtime due to your wire bird nesting, and the overall cost of difficult aluminum welds. Now consider that your consumable costs will be significantly decreased and your production will increase because your operators will spend their time welding, instead of dealing with wire feed issues. Let me know what you think…Post your comments and questions.
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August 21st, 2006 at 3:39 pm
Greetings. I do not absolutely agree with you, but everyone has the right on own idea.