Spool gun aluminium welding

[Sub-arc]

It would cost very little so try the above std euro torch fix and as Matt said bring the liner through the nut on the the torch and right up to the feed rolls.
Probably only able to push NG6 5356- 5% Mag though, which is not the cleanest of wires to use.
If spending a few quid, I'd deffo go push pull on one of your synergic plants. Main reason being- you never know what jobs are going to come up and if you have the right kit then you can go for those jobs.
A pp torch can run most Al wire variants. pp with 4043 looks the dogs bits when finished.

 

[Welderpaul]

As above.

If your going to use the Saprom, get some 1.2mm wire and it'll weld the 2mm fine. You'll need a Alu liner re-tooling kit (about £20) and some 1.2mm Alu U groove rollers (about £30 each x 2 req)

Take out the brass capillary tube out the inside of he central connector and run the new liner straight through directly to the rolls.

Don't bother with a spool on gun, waste of time in comparison. Also Pulse won't work with the Spool on gun only standard settings, so 2mm would be a bit challenging. in order to use Pulse you either need to use a standard type euro torch or a Push/Pull gun, but then to complicate even further you can have a analogue Push/Pull or a digital Push/Pull, analogue are simple/Stupid where as there is very little communication between the two drive systems, where as the digital system allows complete synchronisation between the push and pull motors.

For the job your describing the torch you already have with the correct liner and rollers will **** it

Is 4043 the best wire to use on 1050 or is there an alternative grade which may feed better. The welds are not structural.

 

[hotrodder]

1050 or 1450 is the best wire for welding 1050 IMO but maybe not so much from a MIG feedability POV as it's even softer than 4043. It's American so some of the designations differ a little (1xxx series are near as damn it all the same)* but there's a filler wire selection chart here which grades things on ductility/strength/corrosion resistance etc. 4043 wins on ease of weldability (solidification cracking) and strength (mute point with butts as the HAZ will be the weak link) but is useless if the parts will be anodised for appearance (turns a manky grey colour). 1050 offers a better colour match, is less brittle and (with TIG at least) produces a nicer looking weld (mirror like shine).


* they're all commercially pure aluminium with tiny differences

 

[Lewis Medlock]

Magnesium based wire will feed with less hassle, can you hire a MIG set for the job?

Shame you're not closer I've got just the machine for the job and no work for it


All the best, Jim

 

[normspanners]

Any body tried one of these they are cheap!!?


http://www.ebay.co.uk/itm/MIG-TORCH-EURO-TORCH-ALIMINIUM-WELDING-TORCH-SPOOL-GUN-/160949305924?pt=LH_DefaultDomain_3&hash=item2579538244

anybody tried one ??

 

[BillJ]

anybody tried one ??

Duty cycle: 90A@35%

I'm not sure that will be enough for welding aluminium.

 

[normspanners]

HI BILL

I'm not sure that will be enough for welding aluminium.

maybe good for leaving on a LOW POWER machine for small quick one off's though. OR!
I was wondering about using one with a couple of big 12v batteries in series for field/rally work like the american 'ready welder' , What do you think?

 

[Welderpaul]

Ordered the wire, rollers and liner today. Will report back with some pictures once i've had a go at it

 

[matt1978]

I am doing some on the exhibition, same set up as you Paul, Saprom SpeedPulse S5. Using 4m MW 5800 PM torch (exactly like yours) 1.2mm 4043 and 100% Ar. Works great. When you got the stuff drop me a text and ill send you some settings to try

 

[Welderpaul]

Cheers Matt, rollers, wire and liner turned up today. Got gas, so ready to rock and roll.

 

[Hitch]

What gas are you running, Alumax?

 

[Welderpaul]

What gas are you running, Alumax?

Pure argon

 

[lincoln17]

Hi, I don't know if this might be of interest, but I looked at push pull torches a few years ago. I was building an alloy shelter deck for a customers 50 foot fishing boat, I hired in a 400amp synergic kemppi mig and intended using it with a push pull torch. The welding rep suggested I use a new torch Kempis had introduced called a weld snake. The torch is 10 metres long and has no pull motor, the torch looks like a normal mig torch, I was pretty sceptical as I had had problems with 4m torches in the past, but agreed to try it. I put 8 6.5kgs reels of 5356 1.2 wire through that machine and I never had one birds nest or stoppage. I used around 6 tips, I seem to remember they were 1.4mm and about twice the length of a standard tip. I sited the machine on the boats deck and only had to move it a couple of times throughout the whole job. There was approx 40 8x4 sheets of 4mm alloy, miles of 50 x 50 x6 angle and a few lens of 8 inch alloy channel.
When I put the Kempis back I kept the torch and have used it on my LN25 feeder again with alloy wire with out any problems. I can't remember what they charged me for it but it might be worth asking for a demo on it if it is of interest to you.
Regards James