welding aluminium with kemppi 2501

[bigwillyz]

hi

has anyone tried aluminium welding with a kemppi?
asking as ive tried and it works ok for a bit then the
wire feed picks up and makes a nice birdsnest!

ive been told you can get different rollers for aluminium
wire and just wonderd if this was right

the wire is 1.0mm with tension set up so it slips if i hold the reel

thanks

mike

 

[shenion]

Are you using a 1.2mm tip electrode?

Use a bit larger torch/work gap: 1/2"-3/4", helps keep the wire from sticking to the electrode.

 

[pedrobedro]

As mr Henion says, larger tip and preferably teflon liner and keep the cable as straight as possible. It's not just Kemppi, aluminium needs special consideration or dedicated tackle if you are going to do a lot of it.

 

[bigwillyz]

im using teflon liner with 1.6mm tips im told you can get
nylon rollers which dont make the wire as oval
if that makes any sense

 

[malcolm]

Is there a gap between the liner and the rollers and is that where it is birdsnesting? I cut my liner to shape to fit as close to the rollers as possible (you've covered most of the other stuff here http://www.mig-welding.co.uk/aluminium-setup.htm )

I never felt the need for different rollers - mine were smooth V shape, and worked OK with the tension backed right off. Aluminium against steel is quite grippy. U shaped rolers are available. Hadn't heard of nylon ones.

 

[Paul.]

Some high end migs use nylon rollers for ally, my Saf octipuls has a 4 roller setup with nylon lower rollers for ally and steel flat compression rollers, to help feeding I also slip a short length of old liner between the reel and the infeed side of the rollers, it helps to straighten the wire before it gets to the feed mechanism. contact tip quality has a big effect with feeding ally as well, the bore of the tip needs to be as smooth as possible to prevent arcing between the tip and the wire, genuine Saf tips are sintered over a smooth mandrel when they are made, if you have a snag and try to drill or clean out the tip with a drill or tip cleaner it can create problems with arcing and sticking at the tip,

 

[bigwillyz]

i might have got got that wrong about nylon rollers
ive got red rollers and ive been told i need white ones for aluminium
btu there 50 quid

i think it might be the steel insert that goes from the rollers to the
lance i might get abit of teflon and make something to go in there

thanks

mike

 

[Jake SS]

If possible install your teflon liner all the way from your drive rollers in one piece.
The 1.6 tip is way too big for 1. al, can cause arcing of wire to tip. Use no larger than 1.2. Can get specific tips for al.

Cheers

 

[RealWeld]

Buy a spool-on torch if your doing a lot of ali welding. Makes life a lot easier.