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Basic guide line to follow when MIG welding aluminium : Set the power source for reverse polarity (DCEP). 100% argon shielding gas is generally used for MIG welding aluminum. Use a wire diameter appropriate for your application. Generally, thicker wire works better for thicker applications and vice versa. Use the appropriate wire type. ER4043 and ER5356 are the most common wire types for welding aluminum. However, they have different properties and melts at a different speed, which can affect your desired result. When installing the wire spool, check both the spool tension and the drive-roll tension. The spool tension should be less than what would be set for steel wire. Drive-roll tension should provide an even wire-feed rate. Too much or too little drive-roll tension can cause burnback. When installing the gun, be sure the liner extends from the outlet guide back into the drive roll and as far into the contact tube adapter as possible. If the liner is cut too short, it can cause the wire to tangle, creating what is called a bird nest. Because aluminum forms a hard oxide layer when exposed to air, it is necessary to brush the weld area with a stainless steel wire brush before welding. This will help break up the oxide layer. Remaining oxide will be burned off during the weld process. To ensure good arc starts, the end of the wire should be clipped. This removes any balled end that may have formed during welding. The travel speed for welding aluminum is faster than that for steel due to the high thermal conductivity of aluminum. If travel speed is not increased, excessive melt-through is likely on thin aluminum. Periodic inspection of the MIG gun and contact tip will prevent many of the wire-feeding problems associated with aluminum welding. Finally, store aluminum wire in a plastic bag to protect it from dirt and moisture
Summarize Mig Weld Process With the gas supply and the welding machine turned on the operator can begin welding. If you are welding in outdoor conditions you may need a protective shield to prevent gas from being blown away from the weld area. If you have an automatic welding helmet turn on the power switch. Using a non auto helmet lower the hood in preparation to weld. Never attempt to used welding equipment without a certified helmet. Hold the welding gun at a 90 degree angle to the work and pointed at 10 degrees towards the line to be welded. Squeeze the trigger on the mig gun. Once the weld begins move slowly up the travel line, all the while ensuring that you have a 'pool' of molten metal at the weld zone.