Thread: Help welding Ally

Hi Smicko
Sorry ,No can do. Aluminium must be welded with an AC Tig unit. Aluminium capable Tigs are available as AC or
AC /DC units.
Yes there are cheap ones on Ebay and thats exactly what you will get- see the big history here in archives on cheap E bay tigs and welders.

When you search for the price, be sitting down as you will fall down from the shock. Even if you pick up an old AC unit with HF you still will come in around $1000.Are you still that keen? For that sort of money will get the chassis made for you.

If you have not welded before, the skill level may well be, way above the level you are capable of.

Sorry to put a dampener on things but its the truth.

Grahame

Ally can be welded with MIG, its just not as pretty as TIG.

Originally Posted by Grahame Collins

Hi Smicko
Sorry ,No can do. Aluminium must be welded with an AC Tig unit. Aluminium capable Tigs are available as AC or
AC /DC units.
Yes there are cheap ones on Ebay and thats exactly what you will get- see the big history here in archives on cheap E bay tigs and welders.

When you search for the price, be sitting down as you will fall down from the shock. Even if you pick up an old AC unit with HF you still will come in around $1000.Are you still that keen? For that sort of money will get the chassis made for you.

If you have not welded before, the skill level may well be, way above the level you are capable of.

Sorry to put a dampener on things but its the truth.

Grahame

Thanks Graeme, I go alright on the old arc welder in the shed, just getting the right info to make the right decision.

Originally Posted by martrix

Ally can be welded with MIG, its just not as pretty as TIG.

Thanks for the reply, I'm not too concerned about it being pretty have been thinking about getting a mig for a while. I was looking at a transmig 200 and if it is going to be suitable for 3mm ally then I may go down that route.

Have been looking at new ac/dc tigs for a while now and the entry point is a 30kg jasic 200 @ around $2000 there are several all made in the same factory badged diffrently.
Unfortuantly the brief case model that I would love is $5000 , a tad too much

With a gallon of flux and infinite skill and dedication you could torch weld it- also need a cobalt blue lens. TIG would be same speed and except for localized heat would take about the same time as torch. By the time you will be done, either method, you can probably certify.mt

Hmm, looks like the mig is the go but can someone please confirm the ability to weld 25x25x3mm shs with them.
From what I understand it is a fine line between speed amps and blowing holes but doable with practice.

Hi Smicko,

On Aluminium to run effectively ,the mig must work in spray arc.The means a mig capable of 180 amps or better.

That is very hot on a little box section,I would have concerns about the ability of the light thickness /volume of metal to disappate the sudden heat build up.

It probably means a vertical down wash, but I would not take this as a definitive answer.It needs some one to do this as a experiment to see what happens and report back.

Grahame

Yes 3mm ally can be migged and successfully.The biggest trouble your going to have is its only 25mm.You have nearly finished the weld by the time you have the heat into it. 38mm box or 50x25 will be easier to work with. Both are available in 2.5, 3.0 and 3.2 wall. Capral and Alspec both have 40x40 3.5 wall.
An AC tig would be a more appropriate but as always can you justify the extra cost? Thing is you should be looking for around 200 amps in machines for both processes.When purchasing have a good look at its duty cycle and it's min. amps .

If your having dramas getting your welds up to scratch let gussets and bracing be your friends. 3mm triangular flat bar gussets are a snack to weld either inside or on top of a joint.

Originally Posted by Riley

Yes 3mm ally can be migged and successfully.The biggest trouble your going to have is its only 25mm.You have nearly finished the weld by the time you have the heat into it. 38mm box or 50x25 will be easier to work with. Both are available in 2.5, 3.0 and 3.2 wall. Capral and Alspec both have 40x40 3.5 wall.
An AC tig would be a more appropriate but as always can you justify the extra cost? Thing is you should be looking for around 200 amps in machines for both processes.When purchasing have a good look at its duty cycle and it's min. amps .

If your having dramas getting your welds up to scratch let gussets and bracing be your friends. 3mm triangular flat bar gussets are a snack to weld either inside or on top of a joint.

Thanks Riley, 25 box is as big as i can go and I was definitly going to go down the gusset route to reduce cracking down the track due to vibration. Is it possible to preheat the area to be welded with a blowtorch or similar to get a better result?

Originally Posted by Grahame Collins

Hi Smicko,

On Aluminium to run effectively ,the mig must work in spray arc.The means a mig capable of 180 amps or better.

That is very hot on a little box section,I would have concerns about the ability of the light thickness /volume of metal to disappate the sudden heat build up.

It probably means a vertical down wash, but I would not take this as a definitive answer.It needs some one to do this as a experiment to see what happens and report back.

Grahame

http://www.justtools.com.au/prod3488.htm

Hi Graeme, this is what I am looking at, whaddaya reckon?

Looks a pretty good unit to me ! Good price !

Grahame

Originally Posted by Smicko

Thanks Riley, 25 box is as big as i can go and I was definitly going to go down the gusset route to reduce cracking down the track due to vibration. Is it possible to preheat the area to be welded with a blowtorch or similar to get a better result?

You shouldn't need to .
The 200 CIG should have enough balls the 220 may be a bit better for the extra 300 . I have a 3 phase CIG (Transtig EC250) it has never skipped a beat in 10 years.
My preferences lie with SAF, Lincoln and Miller but as I mentioned the CIG has never let me down.
Seeing that you hope to run ally you will need U rollers not V and don't go too thin on the wire 0.9 or 1.0mm . Elevating the remote or power source will help with feeding ,most units have lifting lugs for this very reason.. If you can, get a 4 roller or a remote rather than a compact .... all these cost though and a budget is easy to destroy! You will also need a Teflon liner in your gun. Check you can do these prior to purchase. Kempi make a great ribbed lead/gun for ally.
You will need 100% Argon as there are no ally flux core wires .

You will more than likely need a 15 amp outlet with a 20 amp breaker if you are running a 200.

Looking at the specs I suspect the 220 is more for you.

200 vs 220


• Welding current range: 30-200 amps. vs 30-220 amps.
• Duty Cycle: 15% at 190 amps. Vs 25% at 220 amps.
• 8 Fine Welding Voltage Settings. vs • 16 Fine Welding Voltage Settings. (Thats a biggy!)
• No Adjustable Burnback Control. vs • Adjustable Burnback Control.