What You Need to Know Before Buying a Mig Aluminum Welder

Before you purchase a mig aluminum welder, you’ll want to know a few things. First, you’ll need an electrode. For most jobs, an ER4043 electrode will work just fine. It is significantly softer than an ER5356 electrode. You’ll also need filler materials. These will depend on the base material, but filler alloy charts are available to help you choose the right ones. Finally, you’ll want to use a shielding gas to protect the weld from contamination. This is important to avoid a high level of porosity in the weld, and a shielding gas will keep out common gasses.


MIG aluminum welding requires spray transfer, whereas short-circuit transfer is used for welding steel. The arc forms when the wire touches the metal, extinguishes when molten filler metal falls into the weld pool, and then starts all over again when the wire feeder pushes more wire into the metal. This process repeats itself many times in a second. The resulting arc is visible to the naked eye, and it is a critical aspect of MIG welding.

While Argon is nontoxic, there are potential health hazards associated with welding with it. Although argon does not support combustion, it can reduce the amount of oxygen in the air, which can cause respiratory problems for welders who are oxygen-dependent. For this reason, it is important to have a well-ventilated work space.

Most mig aluminum welders use 100% argon shielding gas, but you can also use a argon/helium mixture. The combination of the two gases increases the arc voltage by two to three volts. This increases the speed of the weld, but requires more post-welding cleanup. Argon-helium shielding gas typically contains about 25% of helium. Helium is another noble gas that undergoes very few chemical reactions, making it an ideal choice for welds with aluminum.

Argon is a popular shielding gas for aluminum welding, and it helps to create a stable arc. It helps with penetration, reduces the amount of arc instability, and widens the weld bead. The amount of shielding gas used depends on the base aluminum alloy and the condition of the finished part.

MIG welding aluminum is not difficult, but it requires the right equipment. You should have a good understanding of the settings on your aluminum welder, and practice on scrap metal before welding anything valuable.


A Helium mig aluminum welder is a type of gas welder that welds aluminum using a constant voltage and constant current machine. It is a good choice for welders that require the best weld penetration and faster travel times. Helium is also lighter than argon, and it produces a hotter arc that improves weld penetration. While helium is not the most economical gas to use for welding, it is effective for many applications. In fact, it can be blended with argon to make welding more affordable. However, helium is not an ideal choice for weld applications that involve stainless steel.

Helium gas is available for mig aluminum welders from many companies. Most reputable companies have a large customer base, and they will be happy to help you with your welds. If you do not want to use the argon gas, try the Helium Tri-mix. This is a gas mix that contains 90% He and 7.5% Ar. It was tested to weld stainless steel parts with high gauge.

Helium is also useful for welding non-ferrous metals. The gas is used in a 2:1 ratio and can generate a wide penetration profile. Using pure argon in a welder will reduce penetration. Moreover, the increased fluidity of the weld pool can cause out-of-position welding.

The benefits of using a Helium mig aluminum welder are clear: it improves weld productivity, which can make up for the gas cost. However, the downside of using it is that helium is expensive and requires a higher flow rate than argon.

Short circuit

If you’re thinking of purchasing a mig aluminum welder for your next project, you may have some questions. For starters, the term “short circuit” refers to the process of welding metal by means of a short circuit. This process is used when welding steel or aluminum, and involves establishing an arc when the wire touches the metal. As the wire passes through the metal, the arc then extinguishes, allowing molten filler metal to drop into the weld pool. The process is repeated many times per second. The arc is visible to the naked eye, and you can see the wire as it passes through the metal.

The polarity of the wire is critical when MIG welding aluminum. You will need to use direct current electrode (DCEP) polarity. As you progress through the welding process, the wire feed speed will determine the amount of amperage you can output. The higher the wire feed speed, the more amperage you will need to complete the project. You should be aware, however, that too much amperage may result in a loss of coverage.

When welding aluminum, the gas used for shielding must be argon or an argon-helium mixture. This is because carbon dioxide is highly destructive to aluminum and will create a severely compromised joint. Straight argon gas is the least expensive option, while adding helium improves the penetration and heat input. However, it is also expensive and reduces the quality of the arc.

Another alternative is to use a DC pulsed MIG power source. With this method, you can create a DC pulsed weld, which is a low amp, low volt transfer mode.

Spray transfer

If you’re using a MIG aluminum welder, you’ve probably heard of the term “spray transfer.” It refers to the phenomenon of welding aluminum without the tip of the wire ever entering the weld puddle. This technique uses a shielding gas, such as Argon or a mixed Argon/helium gas. The spray is produced by a wire that is placed at an exact distance from the metal surface being welded.

Before welding, you should clean the workpiece thoroughly to remove any aluminum oxide. It is best to use an aluminum wire brush rather than a steel one, as steel wire brushes can contaminate the weld. You should also increase the speed of the welding process to avoid overheating the base metal. When MIG welding aluminum, you should also consider the length of the wire stickout. Compared to mild steel, aluminum gets hotter and requires a longer wire stickout.

While using a MIG aluminum welder, it is essential to follow the manufacturer’s guidelines for wire feed speed. The recommended rate is 20 to 30 cubic feet per hour. The speed of wire feed should match the wire’s diameter. For example, a 0.035-inch-diameter MIG wire needs a 0.035-inch diameter contact tip.

While aluminum is a relatively soft metal, it requires alloying for added strength. The metal is prone to distortion and is sensitive to heat input. Even so, MIG welding aluminum is not difficult as long as you have the right equipment and follow proper procedures. Just remember to practice on scrap before welding anything valuable.

Induction heating

Using an induction heater on a mig aluminum welder can help improve welding penetration when welding thicker aluminum pieces. It can also prevent the metal from becoming too hot, which can lead to distortion when welding aluminium. The heat sink is a metal piece (usually copper or brass) that sits next to the workpiece on a bench.

The use of an induction heating system is one of the safest ways to pre-heat aluminum. These systems have heating coils that don’t use an open flame, so they are much safer than a torch. Induction heating can also be used to prepare consumable wire electrodes for mig aluminum welding. The filler materials used with induction heating are stronger than mild steel and can help prevent deformities.

Induction heating is safer than flame heating because it doesn’t expose the welder to dangerous gasses or an open flame. It can also be adjusted and monitored, and the amount of heat produced can be controlled. Induction heating can also speed up the process of welding by several times compared to torch heating.

Before starting the process, it is important to learn how to properly set the voltage. There is a sweet spot for optimum welding voltage for different materials. Setting the voltage too high will result in excess spatter and too low will cause insufficient fusion. It’s best to follow the manufacturer’s recommendations.

As the metal gets hotter, it loses its elastic modulus. As a result, the yield stress will not be able to support residual stresses. This results in localized plastic deformation. As the metal cools, residual stress is dispersed throughout the weld area.