Mig Welding Aluminum Tube to Plate 1/4" to  5/8" weldersksills video

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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.

scroll down for detailed settings

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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.