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Thread: I Need Advise On Welding Aluminum With A Spool Gun

  1. #1

    Default I Need Advise On Welding Aluminum With A Spool Gun

    This is my first weld with a spool gun. Please advise me on adjustments to get a sound, good looking weld.
    The aluminum is new 5052-H32 3/16" wiped with acetone.
    I-MIG 250P set to 23v 300 ipm (330 ipm is the maximum I can get with this spool gun)
    3/64" ER5356 wire
    15 lpm argon
    Arc force 7.5

    Click image for larger version. 

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    Last edited by zoama; 06-29-2014 at 05:02 PM.
    2013 250EX : SSC Pedal : I-MIG 250P 20' Profax gun : Power Plasma 60 p80 torch : 3M Speedglas 9100XX : Evolution Rage 3 DB cold saw

  2. #2
    Join Date
    Oct 2012
    Location
    Canada, Suttonwest, Ontario
    Posts
    676

    Default

    Zoama
    i just got mine working with a lot of help from Yofish the biggest thing form was that I had the tip out to far it is in now about 1/4" recessed or inside the face of the cup that made a big difference. The second was wire speed was to fast. I slowed the wire down it is at about 210 ipm. but all guns and machines are different I have the same gun as Yofish so it made it easer to get the settings closer.
    My settings are on the MTS250S:
    100% argon @ 25 CFM or 15 LPM
    Wire speed at 210 IPM shown on the machine or #3 on the gun
    Voltage that worked well for me was 20.0V to 20.5V
    Wire size .047 Grade 4043
    Mig (Wave Form Control) not Arc force set at 2
    Aluminum was 6061T6 .132 thick and the flat piece was .188 thick.
    Pics on (http://forums.everlastgenerators.com...ted-to-MTS250S) number 42 are the above settings.

    Yofish or other aluminum Spoolgun welders will give you a better idea of the setting with your machine, I do have a i-Mig250 but I have not put my second 30A gun on it yet it needs to rewire.
    Everlast PowerTig 325EXT (Canada)
    Everlast Power I Mig 250 (Canada)
    Everlast PowerPlasma 80S (Canada)
    Everlast PowerCool W300 (Canada)
    Everlast PowerMTS 250S Fitted with a 30A Spoolgun(Canada)
    Miller Dynasty 400 wireless(Canada)
    Millermatic 252 plus 30A Spoolgun(Canada)

  3. Default

    My advice? Too much wire. Set arc force to zero. Rinse, repeat until spatter disappears.

    EDIT: Also, it helps weld appearance to mechanically remove the mill surface with SS wire wheel or abrasives. Less stuff will 'bubble up'. Welding 5000 series plate with 5000 wire will produce smut, there is just no way around it. A more radical gun angle helps some as does a little more Ar. Blueshield also helps but who wants to pay for it?
    Last edited by Yofish; 06-30-2014 at 04:03 PM.

  4. #4

    Default

    Quote Originally Posted by Yofish View Post
    My advice? Too much wire. Set arc force to zero. Rinse, repeat until splatter disappears.
    Thank you, I'll give it a try this evening.
    2013 250EX : SSC Pedal : I-MIG 250P 20' Profax gun : Power Plasma 60 p80 torch : 3M Speedglas 9100XX : Evolution Rage 3 DB cold saw

  5. Default

    Quote Originally Posted by zoama View Post
    Thank you, I'll give it a try this evening.

    Any progress?

  6. #6

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    Quote Originally Posted by Yofish View Post
    Any progress?
    Not yet, I've been very busy lately and haven't had the time to work on it. Hopefully I'll have time this weekend.
    2013 250EX : SSC Pedal : I-MIG 250P 20' Profax gun : Power Plasma 60 p80 torch : 3M Speedglas 9100XX : Evolution Rage 3 DB cold saw

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