Aluminum MIG Welding Settings Chart

MIG welding is a preferred option for many welders when working with different types of metals, including aluminum. This type of welding technique is highly effective in welding aluminum and is also cost-efficient, making it a popular choice among welders. Furthermore, MIG welding ensures that the welding process does not cause a significant dent in their finances.

If you’re an aspiring welder who wants to venture into MIG welding with aluminum, it’s essential to have a guide that can provide you with the optimal settings for working with this material. With the right settings, you can achieve better results and improve your welding skills.

This post provides a list of recommended settings for aluminum MIG welding. If you’re looking for guidance on working with aluminum, you can browse through this article and select the settings that are most suitable for your specific project. These settings have been carefully selected to ensure optimal results when welding with aluminum.

Aluminum MIG Welding Settings Charts

We’ve included charts in this article that outline the necessary wire speed and voltage settings for MIG welding aluminum. However, before utilizing these values, we recommend that you have a good grasp of the properties of the metal you’re working with. Additionally, it’s essential to take into account the amperage settings and the nature of the task you’ll be undertaking.

Aluminum MIG Welding Settings Chart for 0.30 Wire Size (120-volt input) ( Solid Wire 4043)

MaterialPolarityShieldingGasVolt/Speed Settings for .035Volt/Speed Settings for .049Volt/Speed Settings for .075Volt Setting for .125
AluminiumDECP100% Ar18/23420/300

Aluminum MIG Welding Settings Chart for 0.35 Wire Size (120-volt input) ( Solid Wire 4043)

MaterialPolarityShieldingGasVolt/Speed Settings for .035Volt/Speed Settings for .049Volt/Speed Settings for .075Volt Setting for .125
AluminiumDECP100% Ar18/23520/278

Aluminum MIG Welding Settings Chart for 0.30 Wire Size (240-volt input) ( Solid Wire 4043)

MaterialPolarityShieldingGasVolt/Speed Settings for .035 “Volt/Speed Settings for .049″Volt/Speed Settings for .075″Volt Setting for .125″VoltSetting for . 187″ Volt Setting for .25″Volt Setting for .375″VoltSetting for. 5″
AluminiumDECP100% Ar18/35022/39524/44026/48528/530

Aluminum MIG Welding Settings Chart for 0.35 Wire Size (240-volt input) ( Solid Wire 4043)

MaterialPolarityShieldingGasVolt/Speed Settings for .035 “Volt/Speed Settings for .049″Volt/Speed Settings for .075″Volt Setting for .125″VoltSetting for . 187″ Volt Setting for .25″Volt Setting for .375″
AluminiumDECP100% Ar18/35022/39524/44026/48528/530

Aluminium MIG Welding Settings for Aluminium 4043

Material  UsedWire Type and Polarity SettingSuggested Shielding Gases 20-30 cfh flow rateDiameter of Wire Voltage/ Wire Feed Setting for 0.60 inchesAluminumVoltage/ Wire Feed Setting for 0.105 inchesAluminum 
AluminiumAluminium 4043100% Argon0.30 mm3/90 5/90
AluminiumAluminium 5356100% Argon0.30 mm2/1004/100

Aluminum MIG Welding Settings Chart for 0.30 Wire Size (120-volt input) (Solid Wire 4043)

When using a 0.30 diameter aluminum wire, it’s important to determine the optimal MIG welder settings based on the thickness of the aluminum sample you’re working with. For instance, if you’re welding an aluminum sample that is 0.75″ thick, the recommended voltage and speed settings would be 18 and 234, respectively. It’s crucial to adjust the settings accordingly to ensure the best results for your specific project.

Aluminum MIG Welding Settings Chart for 0.035 Wire Size (120-volt input) (Solid Wire 4043)

As a novice welder, it’s still possible to work with a combination of 0.035/120v/Aluminium Solid Wire. For example, if you’re using these parameters with 0.125″ aluminum, it’s recommended to set the voltage and speed settings to 18 and 235, respectively. However, if you’re working with aluminum that’s around 0.125″ thick, it’s best to use settings of 22 and 395 for voltage and speed, respectively. Adjusting the settings according to the thickness of the material is essential to achieve optimal results.

Aluminum MIG Welding Settings Chart for 0.030 Wire Size (240-volt input) (Solid Wire 4043)

If you’re planning to use a 0.030″ wire size, 240-volt input, and aluminum solid wire 4043, it’s crucial to determine the ideal settings for these conditions. For instance, if you’re working with 0.75″ of aluminum, it’s recommended to set the welder to a voltage and speed of 18/350. On the other hand, when welding 0.125″ aluminum, it’s best to maintain a voltage and speed setting of 22 and 395. Adjusting the settings based on the thickness of the aluminum is essential to achieve the best possible outcome for your welding project.

Aluminum MIG Welding Settings Chart for 0.035 Wire Size (240-volt input) ( Solid Wire 4043)

If you’re working with a 240-volt input, you can weld different thicknesses of aluminum using the appropriate settings. For instance, when using an 0.035 wire size and welding aluminum that is 0.375 inches thick, it’s recommended to set the voltage to 28 and the speed to 530. Adjusting the settings according to the thickness of the material is essential to ensure a successful welding process.

Aluminium MIG Welding Settings for Aluminium 4043

MIG welding can be applied when working with 0.60-inch Aluminium 4043. For instance, if you’re using 100% Argon and a 0.30 diameter wire, it’s recommended to set the voltage to 3 and keep the wire feed at 90 when welding. However, if you’re working with 0.105″ of the same aluminum, it’s best to set the voltage to 5 and adjust the wire feed to 90. Adjusting the settings based on the thickness of the material is crucial to ensure a successful welding process.

Aluminium MIG Welding Settings for Aluminium 5356

When adjusting the MIG tool for 0.60″ Aluminium 5356, it’s recommended to set the MIG voltage to 2 and maintain a wire feed of 100. However, when working with 0.105″ aluminum, it’s best to set both the voltage and wire speed to 4 and 100, respectively. Adjusting the settings based on the thickness of the material is crucial to ensure optimal welding results.

How many Amps Does it take to Weld Aluminium?

Experts suggest that 1 amp of electricity is sufficient to weld every 0.001 inches of metal under consistent conditions. However, determining the appropriate amperage also depends on various factors, such as the thickness of the material.

What Polarity Do I Use When MIG Welding Aluminium?

When working with aluminum, it’s important to set the feed welder to electrode positive polarity, which generates about two thirds of the current. It’s crucial to ensure that the welder is switched to this setting while using this polarity.

Do You Push Or Pull when MIG Welding Aluminium?

When MIG welding aluminum, it’s recommended to use the forehand push direction. This movement helps to ensure that the shielding gas adequately covers the gas while welding.

Aluminum MIG Welding Tips and Tricks

If you’re seeking a straightforward approach to achieving optimal results for your Aluminum MIG Welding endeavors, consider the following tips.

Use High-Quality Wire

In addition to possessing excellent welding abilities, employing top-notch wires can be beneficial for your work. Rather than using just any wire, seek out a brand that provides a consistent cast and helix with a smooth finish.

2. Handle the Spool Correctly

When using the wire for your aluminum project, handle it with care. Begin by lifting the spool from the center bottom and ensure that the wire doesn’t slip out of your grasp.

3. Use the Right Equipment

Select contact tips specifically designed for aluminum welding to avoid any potential errors that can arise from using the wrong tips.

Frequently Asked Questions

When setting up MIG welding for aluminum, there are several factors to consider:
  1. Wire type and diameter: Use aluminum welding wire specifically designed for MIG welding aluminum. The wire diameter will depend on the thickness of the aluminum being welded.
  2. Shielding gas: Use a shielding gas appropriate for aluminum, such as pure argon or a mixture of argon and helium.
  3. Wire feed speed: Adjust the wire feed speed to control the deposition rate of the weld metal.
  4. Voltage: Set the voltage to achieve the desired heat input for the thickness of the aluminum being welded.
  5. Travel speed: Control the travel speed to ensure proper heat distribution and penetration.
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MIG (Metal Inert Gas) welding is a welding process that uses a consumable wire electrode and an inert gas, such as argon or a mixture of argon and carbon dioxide, to create an electric arc between the electrode and the workpiece. The electric arc produces heat, which melts the electrode and the base metal, forming a weld joint.

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When MIG welding aluminum, you can use either pure argon or a mixture of argon and helium as the shielding gas. The choice of shielding gas depends on the specific application and the thickness of the aluminum. Generally, pure argon is suitable for thinner aluminum sections, while a mixture of argon and helium provides better penetration and heat transfer for thicker aluminum sections.

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The wire diameter for MIG welding aluminum will depend on the thickness of the aluminum being welded. Typically, for thin aluminum sheets (up to 1/8 inch or 3.175 mm), a 0.030-inch (0.8 mm) wire diameter is commonly used. For thicker aluminum (up to 1/4 inch or 6.35 mm), a 0.035-inch (0.9 mm) wire diameter is often preferred. However, these are general guidelines, and it’s important to refer to the manufacturer’s recommendations for the specific wire diameter to use.

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Aluminum is commonly welded using MIG welding because it is a versatile and efficient process for joining aluminum. MIG welding provides good control over the welding process, allows for high welding speeds, and provides a strong and durable weld joint.

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Conclusion

In conclusion, MIG welding aluminum requires precise settings to achieve optimal results. The ideal settings vary depending on factors such as the thickness of the aluminum, wire size, voltage input, and amperage. It is crucial to use contact tips designed for aluminum and high-quality wires to ensure smooth and consistent welding. Other factors such as polarity and welding direction also play a significant role in achieving great results. By following these tips and guidelines, even amateur welders can successfully work with aluminum using MIG welding.

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