Welding aluminum presents a very different set of challenges compared to welding steel. It oxidizes almost immediately and its high thermal conductivity causes it to dissipate heat rapidly. These conditions require more heat input and faster travel speeds than with steel. Most people assume you have to have a TIG welder to weld aluminum. But there is a way to weld aluminum with a MIG welder.
Enter the spool gun, the game-changer for MIG welding aluminum. This accessory holds a spool of aluminum wire and feeds it directly to the weld zone. Its short wire-feed path dramatically reduces the binding or “bird-nesting.” This setup makes it possible to weld aluminum without learning a whole new skill set required for TIG welding.
In this video, our friend Vince shows you how it’s done. He covers how to dial in the right wire-feed speed, travel technique, and shielding gas to successfully weld aluminum. With his tips and a little practice, MIG welding might be an alternative to TIG for your next aluminum project.