Welding Aluminum with MIG-205DS
I decided to play around with trying to MIG weld aluminum with my MIG-205DS.
I purchased one of these PTFE liners:
https://www.ebay.com/itm/172173869028
One of these U groove drive rolls:
https://www.ebay.com/itm/184314295365
And a 1 lb roll of ER4043 0.030 Aluminum wire.
I initially had some problems feeding the wire. I had to crank the drive roll tensioner all the way down to get it to feed without slipping. That was putting a flat edge on the wire.
I removed the steel spiral inlet guide (it unscrews screws out of the plastic guide holder). I put some shrink tube over the end of a piece of the PTFE liner I had trimmed off to make it big enough to stick in the plastic inlet guide holder (a piece of electrical tape would probably work also). See attache picture.
I removed the spring from the wire spool holder to lighten the friction.
This allowed me to back off the drive roll tensioner to the 2 value and not slip. This fixed the flat side on the aluminum wire and the wire feeds good now.
However, I was still having problems welding. I was telling the machine I was using 0.023" wire. I tried both the MIG and MAG settings but the wire doesn't appear to be coming out fast enough compared to the current.
I asked Yeswelder if they had a chart for wire feed speed vs amperage. To my surprise, they emailed me a chart. I've attached a screenshot of the relevant settings (the website wouldn't let me upload the whole PDF). It appears to be a work in progress.
The values for current and voltage are the same or very close as you get when you use the synergic Thickness setting with the exception of the setting for 0.023" wire when it gets above 2.5mm thick. Then the settings just don't make sense.
I entered the values into a spreadsheet and charted Wire Feed Speed vs Amperage for the various wire diameter and MIG/MAG settings (I stayed consistent with Yeswelders MIG/MAG terminology even though it isn't technically correct). It became obvious when I compared these charts against what Lincoln recommends (screenshot attached) that there isn't a combination that provides a fast enough wire feed speed for 0.030" wire for a given amperage. However, it appears that you can get appropriate feed speeds for 0.035" wire. I tried to attach the spreadsheet but the website wouldn't let me. I attached a couple of screenshots for the 0.023" wire but I ran up against my attachment limit. I'll attach the rest in a subsequent post.
I've ordered some 0.035" ER4043 wire and some 0.040" tips. I'll see if I have better luck with that.