TIG welder or MIG Spool Gun for Aluminum

[Odyknuck]

I have been looking into adding Aluminum Welding to my shop tools. My internal debate is I will not have enough projects to justify the cost a new TIG machine. Also that I have never used a TIC machine, only MIG and Stick. I like the speed of them versus the TIG process. Nort real concerned with nice looking fancy welds as long as they are strong. I already have a Lincoln SP175 that can be converted to use the 100SG spool gun for around $200.00. My useage is strickly for my Off Road Hobby. 3/16" max Aluminum for skid plates, fuel tanks etc. Anything thicker I have the option to have my buddy weld at no cost. Anybody have experience with a spool gun or thoughts on both process that they can share .

[blacksmith]

Check this post:

http://www.everlastgenerators.com/fo...ighlight=spool

[CGCINC]

I really like the control of TIG along with a pedal for Aluminum welding. You also get a really nice looking bead.
The only experience with an Aluminum spool gun I've had was in welding class. It seemed to work fine but was not as pretty as Tig...

[EchoSixMike]

Aluminum spray is great for production stuff, we're currently using a Miller spool gun for 1/8" aluminum sheet metal and TIG for the heavier structural stuff. With MIG you're going to have some soot cleanup issues, but NBD IMO. MIG is a much easier skillset, so you're probably a lot better off if you get the spool gun and go to work and just use your buddy for any thick stuff you get. TIG is pretty and great for thin stuff where MIG would slag it. S/F.....Ken M

[fdcmiami]

Aluminum spray is great for production stuff, we're currently using a Miller spool gun for 1/8" aluminum sheet metal and TIG for the heavier structural stuff. With MIG you're going to have some soot cleanup issues, but NBD IMO. MIG is a much easier skillset, so you're probably a lot better off if you get the spool gun and go to work and just use your buddy for any thick stuff you get. TIG is pretty and great for thin stuff where MIG would slag it. S/F.....Ken M

there is nothing more versatile for welding aluminum than a spool gun. the above is kind of confusing. of course you have to have a spool gun of good quality. i own two miller 30A's, one with flex neck that i use the most and one with standard neck.

[225]

I haven't TIG welded aluminum but a few times. And I have to say, TIG is where it's at.

Also, I don't know why a lot of people are scared to use TIG. It's not that hard, just takes a little practice. I just built a whole trailer using TIG.

My attempt at TIG aluminum:



My ac balance was way too high. But other than that, it's sounds weird because of being on AC.

[EchoSixMike]

there is nothing more versatile for welding aluminum than a spool gun. the above is kind of confusing. of course you have to have a spool gun of good quality. i own two miller 30A's, one with flex neck that i use the most and one with standard neck.

I'd argue versatility; try MIG repairing cylinder head castings. TIG's ability to "clean up" damaged/dirty castings is a critical feature. I should have specified that our spool guns are setup for auto body work; small dia wire for sheet metal. I have a Python push/pull for my PowerMIG, but changing it over is a PITA, so I just TIG structual aluminum; if I was doing production, I'd go through the hassle of setting up the Python. 300+ amp spray arc is brutal. S/F.....Ken M

[acourtjester]

A few years back I bought and Miller mig because it had a spool gun for doing aluminum welding. I have only used it a few time and found some pre-heating of the aluminum is needed to get a weld. I have since bought a Tig welder to do the aluminum welding. It worked much better (I am not a pro-welder) Mig aluminum you need to push weld and the bead is much higher then a tig weld and you still need to get an Argon bottle for either type.

[fdcmiami]

strange advice on these threads. the guy has a 200 dollar spool gun (which surprisingly has some pretty good reviews). from what i read it will serve his purpose and save him some money.

show up on a job with your tig machine, at xxx dollars per hour and tell them you arre going to do the weld out with it. lol

i used almost 20 pounds of wire on this job. rub rail was so heavy i used the pilings to support a trolley setup with two chainfalls then a comealong at the bow to pull it in.

that plate used to retain the piece of rail at the bow in the last pic is half inch to three eighths. it took less than an hour to put in three passes. i've done a ton of this stuff.

not in any way implying that tig welding not important i know it is but believe me, there is no more cost effective way to lay in aluminum wire than a spool gun.

[everlastsupport]

We have a 250EX and *210EXT and a *IMIG-200 and IMIG205 with spool guns for aluminum (* is the ones used most these day). Really depends on the job, but the MIG is normally the winner unless small detailed work or odd metal type is required/used.

fdcmiami: What did you use to groove and clean the salty boat?

[fdcmiami]

We have a 250EX and *210EXT and a *IMIG-200 and IMIG205 with spool guns for aluminum (* is the ones used most these day). Really depends on the job, but the MIG is normally the winner unless small detailed work or odd metal type is required/used.

fdcmiami: What did you use to groove and clean the salty boat?

i used 36 grit flap discs for most of it. sometimes i'll use my skill saw when i have a clump of something, i lay it at an angle and drag it across the weld. cleans up fast, better be holding on though. i use cheap seven and a quarter in blades.

i own a 250ex, very happy with it, and use it when conditions warrant its use.

[fdcmiami]

We have a 250EX and *210EXT and a *IMIG-200 and IMIG205 with spool guns for aluminum (* is the ones used most these day). Really depends on the job, but the MIG is normally the winner unless small detailed work or odd metal type is required/used.

fdcmiami: What did you use to groove and clean the salty boat?

i used 36 grit flap discs for most of it. sometimes i'll use my skill saw when i have a clump of something to remove, i lay it at an angle and drag it across the weld. cleans up fast, better be holding on though. i use cheap seven and a quarter in blades.

i own a 250ex, very happy with it, and use it when conditions warrant its use.

sorry for the double post. added additional pics

[EchoSixMike]

strange advice on these threads. the guy has a 200 dollar spool gun (which surprisingly has some pretty good reviews). from what i read it will serve his purpose and save him some money.

show up on a job with your tig machine, at xxx dollars per hour and tell them you arre going to do the weld out with it. lol

i used almost 20 pounds of wire on this job. rub rail was so heavy i used the pilings to support a trolley setup with two chainfalls then a comealong at the bow to pull it in.

that plate used to retain the piece of rail at the bow in the last pic is half inch to three eighths. it took less than an hour to put in three passes. i've done a ton of this stuff.

not in any way implying that tig welding not important i know it is but believe me, there is no more cost effective way to lay in aluminum wire than a spool gun.

I don't see where we're arguing. I specified the difference between production and not, and recommended a spool gun. As a "hobby" it may be worth it to get superior asthetics, maybe not, personal decision. There are jobs that spec TIG in the field, so it all comes down to the WPS. S/F....Ken M

[fdcmiami]

I don't see where we're arguing. I specified the difference between production and not, and recommended a spool gun. As a "hobby" it may be worth it to get superior asthetics, maybe not, personal decision. There are jobs that spec TIG in the field, so it all comes down to the WPS. S/F....Ken M

ken, given your circumstances i am in agreement with you, sorry if you thought otherwise; plus the fact that if someone is paying my salary i do whatever they say. my posts are not directed to anyone in particular, they are just my opinions based on my experience. i have done a lot of work to this particular boat and the photos i have provided show a wide range of welding situations and with the exception of some new rail i put in nearly everything was welded with a 30A with flex neck attachment (much of it on a raft, overhead). the work displayed may be on a boat but in general this is what you find when your are working in the field. i owned a miscellaneous metals shop back in the nineties and i did a lot of aluminum work in the construction end of the business. if you didn't absolutely have to tig weld it we used a wirefeeder or spoolgun.

[EchoSixMike]

Agree. Most of what I do for welding(that isn't hobby) is repair stuff and the setup and prep(and travel) is most of the work, the welding goes fast. S/F....Ken M