Mig Welding Aluminum is generally more tricky than mig welding carbon steel.
It is not all that difficult but it seems that all the settings and variables are much less forgiving on aluminum.
For this quick video, I used .035" 4043 wire (3/64" would have been better but .035" was all I had in a large spool)
25 volts and 580-600 ipm of wire speed.
A longer stickout of around 3/4" is typically used for mig welding aluminum and since its a spray transfer process so you are not trying to get a bacon fry sound in the arc.
You want a smooth hum to indicate spray transfer.
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WELD PROCESS = GMAW, GAS METAL ARC WELDING
METAL TYPE = ALUMINUM ALLOY
THICKNESS = 1/4" INCH TO 5/8"
WELD TYPE = Fillet
JOINT TYPE = tube to plate
POSITION = 2F HORIZONTAL
VOLTS = 25.0 volts
WIRE SPEED = 590 IPM
WIRE SIZE = .035” 4043
POLARITY = DCEP
GAS FLOW = 25-35 CFH 100% ARGON GAS
CTWD = 1/2” - 3/4"
FILLER METAL = ER4043 .035"
ADDITIONAL SETTINGS =
TIPS:A longer contact to work distance CTWD of 1/2”-3/4” helps with spray transfer aluminum mig welding.