The Ultimate Guide to Choosing Aluminum Mig Welding Wire

Welding aluminum

Aluminum in its pure form is a relatively soft metal that has many uses, but which requires the addition of an alloy or alloys to increase its strength and to add other qualities suitable for different applications. Common alloys are: copper, magnesium, silicon, manganese and zinc. They are identified by their series numbers:

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• Wrought Series Alloy groups
• 1xxx 99% minimum aluminum purity
• 2xxx copper
• 3xxx manganese
• 4xxx silicon
• 5xxx magnesium
• 6xxx magnesium-silicon
• 7xxx zinc
• 8xxx other
• 5xxx magnesium
• 6xxx magnesium-silicon
• 7xxx zinc
• 8xxx other

Aluminum, especially thin-gauge aluminum, presents some unique welding challenges. For many, GTAW is the preferred process, but GMAW offers some obvious benefits: higher deposition rates, less operator training and higher productivity. With these benefits come a few challenges, namely wire feeding and selecting the right type of filler metal and equipment. These challenges can be easily met, however, by knowing the answers to some common questions.

Frequently asked questions 

While filler metal for steel is typically chosen by matching the tensile strengths, strength is only one of the considerations when choosing an aluminum filler metal. Typically, there are several different aluminum filler metals that would be acceptable to use when welding aluminum base materials. In choosing a filler metal, consider:

-Base metal composition
-Ease of welding
-Joint design
-Dilution (when the filler wire and base metal combine in the weld puddle to create a different chemical make up in the weld)
-Strength of the weld
-Hot cracking sensitivity
-Ductility
-Corrosion in service
-Color matching, if the material is anodized
-Elevated service temperature (150-350 Fahrenheit)

Different filler metals address these considerations to varying degrees. In general, if strength is the primary consideration, the filler metal should closely match the base metal in tensile, yield and ductility.

Most consumable manufacturers, as well as the American Welding Society (AWS), offer information listing the relative values of these considerations of their filler metals for each base alloy. Always make sure to use an aluminum filler metal selection chart to address the weld properties listed above.

Traditionally, welders have relied on AWS and wires, as they can be used with the most widely used aluminum alloy base metals. Hobart, however, offers an alternative to filler metals to increase strength and quality. The MaxalMig®  aluminum wire offers approximately 20% higher tensile strength and doesn’t rely on diluting the aluminum base material to gain strength. This feature often allows welders to make smaller, single-pass welds and still get reliable strength. It also helps minimize the risk of distortion since heat input is lower. 

Aluminum as a filler metal has the same oxidation problems as all aluminum. When left open, either on the shelf or installed on the welder, aluminum filler wire will oxidize, which can lead to an erratic arc. The oxidation adds resistance, can produce smut and can change the wire’s ability to feed smoothly. Many operators have spent a great deal of time adjusting tension settings, changing contact tips or checking the shielding gas trying to fix the problem when it was the oxidized wire that was at fault.

Because of its low columnar strength, feeding aluminum wire has been likened to pushing a wet noodle through a straw. Birdnesting, or the tangling of the wire between the drive roll and the liner, is a common, time-consuming and costly problem. Clearing it requires the operator to stop welding, cut the wire, discard the wire in the gun and re-feed new wire through the liner. It also may require cleaning or changing the contact tip because of the burnback caused when the wire stops feeding.

There are several ways to feed aluminum wire: Push only, spool gun, push-pull system and continuous feed push-only system.

Push only: Feeding aluminum wire through a push-only system can be difficult, but it can be done on a limited basis. It requires u-groove drive rolls to provide more surface contact with the wire, adequate drive-roll pressure and the ability to keep the gun cable straight. Any resistance in the line will likely cause the wire to misfeed. Thicker wire, such as 1/16 inch, may be fed consistently in a push-feed system. But for thinner gauges, such as .030 inch, push feeding is not very dependable.

Spool gun: Welding aluminum with a spool gun, such as the Spoolmate™ or Spoolmatic® series of guns, eliminates the possibility of birdnesting by putting a 4-inch (1-pound) spool on the gun, so the wire only feeds a few inches. Spool guns can accommodate aluminum wire diameters from .023 to 1/16 inch and allow the operator to use longer cables (15-50 foot).

A spool gun needs to have the roll changed after every pound of wire is used, compared with the 16- or 22-pound spool on a push-pull system. In tight spaces, the spool may limit access, requiring the operator to use a longer stickout. If the operator is using several pounds of aluminum per day, the few minutes needed to change spools can add up. Also, the chance of burnback exists when the end of a spool is reached, so many operators stop when a few turns are left on the spool.

Push-pull gun: With a push-pull gun, a motor in the gun pulls the wire through the liner, while the motor in the welder or feeder control becomes an assist motor. By maintaining consistent tension on the wire, the push-pull system helps eliminate birdnesting. It is more ergonomic than the spool gun since the weight of the spool is not in the operator’s hands.

Also, the spool needs to be changed less often than on a spool gun and allows the purchase of larger spools. A push-pull gun also allows cables up to 50 feet long. The only disadvantage to push-pull systems is their relatively higher price tag, but the increased productivity and the financial advantage of buying larger spools usually provide a quick return on investment. When you compare the cost of 16 1-pound spools of .035-inch aluminum filler wire with one 16-pound spool of the same diameter wire, plus the time to change 16 spools versus one spool, you’ll see that for high-volume use, a push-pull system makes financial sense. 

A welding distributor, picked at random, lists a price for a 1-pound spool of .035-inch aluminum wire as $11.46. A 16-pound roll lists for $170.24, which works out to a difference of $0.82 per pound. Now, add the time for 16 spool changes (and possibly burnbacks) for the spool gun as compared with one change for the larger spool. At five minutes to change a spool, that’s 80 minutes of extra time for each 16 pounds of filler wire used.

Continuous-feed push system: This is a relatively new addition to the field. This type of system uses a special drive system that maintains continuous contact with the wire and eliminates the possibility of birdnesting since there is no gap between the drive rolls and the liner. While it is limited to pushing the wire 15 feet, the gun is lighter than either the spool gun or the push-pull gun and requires no additional maintenance.

Check out this article for more MIG welding aluminum best practices.

In welding aluminum, choosing the right welding wire is as crucial as the welding process and welding equipment. Aluminum welding wire plays a crucial role in creating quality, long-lasting welds that are worth the wait.

But with so many on the market, how do you choose the ideal aluminum welding wire for your project? Keep reading and we’ll explore the different types of aluminum welding wires, their additives, common issues, and how to choose the best one for your specific needs.

What Are Aluminum Welding Wires?

Aluminum welding wires are specialty wires in welding to connect aluminum materials. Wires are forced through a welding tool to create an electrical arc that fuses the base metal and the filler metal to create a quality joint.

Aluminum wires are of various grades and types developed for different welding processes and applications. The most common aluminum welding processes are TIG (Tungsten Inert Gas) and MIG (Metal Inert Gas). The wire you select will be influenced by the base material, the welding process, the weld strength, etc.

Additives in Aluminum Welding Wires

Aluminum welding wires typically have additives to improve performance. The additives enhance the wire properties, making it simpler to handle and providing solid, long-lasting, and wear-resistant welds.

Magnesium

Magnesium is a common aluminum welding wire additive. It makes the weld stronger and generally gives the wire higher corrosion resistance.

Magnesium appears in ER welding wire, commonly employed to weld aluminum alloys like and . The additive makes the wire suitable for high-strength applications in the auto and marine industries.

Silicon

Silicon is one of the prevalent additives and to the weld more fluid. It lowers the wire melting temperature, flowing more easily and forming a smooth weld pool.

Incorporated into the ER welding wire handy, it is common in welding aluminum alloys like , , and . Silicon also increases the appearance of the weld so that it will be smoother and more aesthetic-looking.

Do High Quality Aluminum Welding Wires Matter?

Yes, high-quality aluminum welding wires are necessary to produce the best results in your welding work. Some of the benefits of using high-quality aluminum welding wires include:

1. Stronger Welds: High-quality wires produce stronger, more resistant welds. This is critical in aerospace, automotive, and construction, where weld strength is paramount.
2. Improved Aesthetic Quality: They produce smoother, better-looking welds with fewer flaws.
3. Less Spatter and Cleanup: They produce less spatter, reducing cleanup time on the weld when the process is complete.
4. Better Feedability: Quality wires have better feedability (i.e., they become entangled less and do not lead to feed issues in the welding machine).
5. Consistency: These welding wires provide more consistent results, something that matters if you’re doing professional-level projects.

ER Aluminum Welding Wire

ER is a common aluminum welding wire. It is an all-position general-purpose welding wire for a wide variety of uses, from automobiles to household appliances.

The ER contains 5% silicon, which increases the weld pool’s fluidity, so welds are more fluid and are less apt to crack. It is especially ideal for welding aluminum alloys and , and is usual in industries that include appearance welds as a consideration, such as bicycle frames and metal fabrication.

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ER Key Properties:

• Tensile Strength: 21,000-33,000 psi
• Melting Range: °F-°F (574°C-632°C)
• Color Match After Anodizing: Gray
• Suitable for Base Materials: , , , and aluminum alloys

ER Aluminum Welding Wire

ER is another widely used aluminum welding wire but with an addition of 5% magnesium, which makes it stronger and more corrosion-resistant. It is used extensively where additional strength is a requirement, but not necessary, (i.e., in marine, aerospace, and automotive applications.)

The ER is ideally helpful for welding alloys such as and , which are common in saltwater applications since magnesium is extremely resistant to corrosion in saltwater environments.

ER Key Properties:

• Tensile Strength: 29,000-45,000 psi
• Melting Range: °F-°F (571°C-635°C)
• Color Match After Anodizing: White
• Suitable for Base Materials: , , aluminum alloys

ER vs. ER

Choose the Right Aluminum Welding Wire for Your Application

Choosing the right aluminum welding wire depends on several factors, including the type of aluminum alloy being worked with, the welding procedure, and the wire diameter.

The Right Wire for Aluminum Alloys

Different aluminum alloys have distinct properties that require different welding wires.

As an example, ER is best used with alloys like and , while ER is better used with alloys like and . Be certain to match the wire with the alloy you’re working with to achieve good, consistent welds.

The Right Wire for Welding Processes

The welding process you’re doing also affects choosing the MIG welding wire. MIG welding is a common procedure for aluminum, and both ER and ER can be utilized with a MIG welding machine.

In case you’re using TIG welding, you can opt for a smaller wire and need to ensure that the wire is clean and impurity-free. Read more in TIG Welding Aluminum Complete Guide and Mastering MIG Welding Aluminum.

Wire Size and Feedability

The wire size is necessary to ensure proper feedability through the welding machine. Thicker wire may be necessary for heavy-duty applications and thinner wire for finer applications.

Aluminum wire is soft, and you may encounter some feeding issues, so it’s best to choose a wire size that your welding machine can feed.

Aluminum Welding Wire: Troubleshooting Common Problems

Poor Quality Welds

Inconsistent welds can be caused by the incorrect choice of wire, incorrect settings, or contamination. Ensure that you’re utilizing the correct wire for the alloy and that the welding machine is set correctly.

Wire Feed Problems

Wire feed issues are frequent while welding aluminum since aluminum wire is soft and can easily tangle. Using a spool gun or push-pull system could enhance the feedability.

Overcoming Oxide Layer

When aluminum comes into contact with air, it creates an oxide layer that may result in low-quality welds. To get over this, scrub the aluminum well prior to welding, and make sure that your welder is set on the proper parameters.

YesWelder: Partnering with a Professional Welding Machine Supplier

If you are looking for quality welding equipment and accessories, YesWelder wholesale is trusted by distributors and buyers.

With a track record of being reliable and affordable, YesWelder offers a comprehensive range of aluminum welding machines. Our products include MIG, Stick and TIG welders, spool guns, and multi-process machines. For a professional welder and a novice, YesWelder has the equipment necessary to achieve high-quality results for aluminum welding needs.

FAQ

What is the ideal wire for aluminum welding?

The ideal wire depends on which alloy you are welding. ER is acceptable for alloys like and , but ER is better for higher-strength alloys like and .

Can I use flux-cored wire for aluminum?

No, there isn’t any flux-cored aluminum welding wire for arc welding. Solid aluminum wire is used with MIG or TIG welding processes.

Why is aluminum welding wire softer than other metals?

Aluminum is a soft metal, and aluminum welding wire is designed to be flexible and easy to feed through welding machinery.

What is the purpose of magnesium in aluminum welding wire?

Magnesium adds strength and increases the corrosion resistance of the weld, making ER a good choice for use in applications exposed to saltwater or other corrosive elements.

How do I prevent feedability problems with aluminum welding wire?

To prevent feedability issues, use a spool gun or push-pull system, which better feeds the wire through the machine.

For more Flux Cored Welding Wireinformation, please contact us. We will provide professional answers.