Aluminum weld settings

[shortarc]

Have a few questions about welding aluminum with a spool gun.

Just bought a Spoolmatic 30H to use on my trailblazer 302, I've welded with all the other processes several years but this is a first for me with aluminum and need some answers.

First I noticed most all the settings I've found call for spray transfer and flat or horizontal, what settings do you use for vertical and overhead, surely must be a way to do that?

Also I noticed that anything under 14ga is not recommended, but can it be done in a pinch after I get used to the process?

And last anyone that uses this same setup have any favorite settings that work the best for different positions and thicknesses.

The wire I picked up is 4043.

Thanks.

[aametalmaster]

I have been spool gunning alum for more than 30 years and found that you have to play each part by ear. There may be a sweet spot where i start but every job needs tweeked. My suggestion is get a pile of alum scrap and start welding like it was a good part. Then you will have a better idea on where your machine likes to be run. And yes you can run alum overhead and if you tack some practice parts together you can master that as well. It will take a little time to get used to everything. Just my thoughts...Bob

[shortarc]

Thanks for the advice Bob. When you do the overhead do you stay in spray transfer or back down and get into short circuit transfer?

[aametalmaster]

Thanks for the advice Bob. When you do the overhead do you stay in spray transfer or back down and get into short circuit transfer?

Short circuit is what i use for every job. My welder is too small to spray...Bob

[captkipp]

Spoolgun.

I think you mean a 30A gun?

Any way use one on the mobile truck quite frequently hooked up to a 24 weld conrol and the TB302. Our learned memeber pointed out a very good point: The charts are good starting places, BUT each job needs to be tweeked for voltage and wirespeed. Unless you have been lucky enough to find a Spoolmatic that is synergic!
For my setup and 1/4" 5052 material using .035 4043 Maxal wire, I start the TB at 20.5 and set the 30A at 4. I adjust from there. Use a little more heat and a little more speed for the 6061 stuff. Good luck with it.

[shortarc]

Thanks for the help guys.

What threw me a curve was that on the Miller welding calculator they said short circuit transfer not recommend. Go figure.

Tomorrow I'll pick up some scrap Aluminum and a bottle of straight Argon see what happens.

I did hook it up yesterday, had a spool of .035 mig wire and found I can get some serious penetration out of the Trailblazer.

captkipp. mistype there it's a 30A.

[shortarc]

Just got it hooked up and tried it out. Whole different ball game from welding steel.

Here is a picture of my first aluminum weld. 10ga 21.6 @ aprox. 270 ips. Kinda crappy with my cell phone but thought I would show it.

Thanks again for the help.

Also .035 4043 wire.

[MMW]

I have found that gun angle is important. Mostly you "push" the gun slighty. From vertical tilt it back 10-15 degrees. Although you can't do this with every weld it is a good baseline. On thick stuff I set my machine to 27.5v & 4.5 to 4.75 on wire speed (3/64 4043 wire). Argon at about 25-35.