Aluminium welding - what I am doing wrong - beginner

[Jetfox]

Hi everyone, I hope this is the right place to ask a question about my welding projects.

I am a beginner and I would like to use my new welder for small home projects.

I am having issues welding aluminum.
Looks like the weld is not connected to the material. It is easy to break it.

Welder: Hobart 210MVP
Voltage: 115V
Settings: 7/70 as chart says
Spoolrunner 100 spoolgun
Wire: 0.030 ER4043
Gas: 100% Argon 30CFH

Welding material: square 1/8 thick 6063T52

[milomilo]

Hi everyone, I hope this is the right place to ask a question about my welding projects.

I am a beginner and I would like to use my new welder for small home projects.

I am having issues welding aluminum.
Looks like the weld is not connected to the material. It is easy to break it.

Welder: Hobart 210MVP
Voltage: 115V
Settings: 7/70 as chart says
Spoolrunner 100 spoolgun
Wire: 0.030 ER4043
Gas: 100% Argon 30CFH

Welding material: square 1/8 thick 6063T52

Post some pics.

[ctbme02]

Hi everyone, I hope this is the right place to ask a question about my welding projects.

I am a beginner and I would like to use my new welder for small home projects.

I am having issues welding aluminum.
Looks like the weld is not connected to the material. It is easy to break it.

Welder: Hobart 210MVP
Voltage: 115V
Settings: 7/70 as chart says
Spoolrunner 100 spoolgun
Wire: 0.030 ER4043
Gas: 100% Argon 30CFH

Welding material: square 1/8 thick 6063T52

Sounds like it's not hot enough. Crank the machine on up and see if your results change, or hook to 220 and try the settings for 220 volts.

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[Jetfox]

Here we go

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[ctbme02]

Here we go

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I'm not seeing penetration into the base metal. Settings need to be hotter.

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[Louie1961]

It is my opinion that you are never going to be successful welding aluminum with that machine on 115 volts. Your wall outlet has to deliver a full 20 amps to get the max output on 115 volts (actually it is 120v in the US, but whatever). If you are using a standard 15 amp outlet, you are already handicapped. Second, that machine is really a 90 amp machine on 120 volts (90 amps @20% duty cycle). You need a minimum of 120-130 amps to weld 1/8th inch material, maybe more. at 120 amps that machine has a 5% duty cycle or less. Finally, in looking at the volt amp curve, even if you get enough amps out of that machine, you likely are not going to get enough volts to achieve the required spray transfer (as least on 120volts).

Plug it into a 240 volt outlet and I'll bet you will see a world of difference. You will be MUCH happier.

[Jetfox]

Thank you so much everyone!
This is such a great forum!

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[welding1]

On aluminum, dont be afraid to turn up Wire speed and volts. Also wire brush or grind to remove the surface oxides.

[danielplace]

Thank you so much everyone!
This is such a great forum!

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Guessing it is not but if the 120 volt outlet your using is a dedicated 20 amp on it's own wire and circuit it could be converted to a 240 volt circuit.

Even if it isn't the materials needed to run a light duty 12 wire 240 volt circuit is not huge. Any electricians around that could help you get a circuit run ?

The price of everything especially wire has skyrocketed but probably best next move if you want to weld aluminum.

[oldwelderman]

On aluminum.......... wire brush or grind to remove the surface oxides.

???
i allways do read, on Al the surface oxides are back as soon as you stop removing them..

[Oscar]

???
i allways do read, on Al the surface oxides are back as soon as you stop removing them..

but the more you set yourself up for success, the better your odds. It's true that aluminum oxide starts developing in just a few nanoseconds after bare fresh aluminum is exposed, but don't fool yourself into thinking it completely self-replenishes to full thickness instantly. In a few minutes the layer will be only a couple millionths of an inch thick. Hardly anything.