Weld Aluminum w/ Stick Welder?

[bighammer]

Just wondering if anybody has tried it. I'm not a great welder and have a basic AC 200A welder. I've done steel and stainless a little bit, butI saw AL sticks at the supply shop. We have some dock legs and related parts for our waterfront that we would like to repair and/or modify. Is welding AL with a stick welder that tough? Or should I just take it to the welding shop and have somebody else do it. (or of course the other option-- Tell the wife I need a fancy MIG or TIG or whatever they're called )



Thanks

 

[jmadden]

Have seen it done a couple times... the result was questionable quality and poor appearance. Like anything there is likely a learning curve before the welds start to turn out... maybe the guy I was watching was too far down on the curve.



If it is a critical weld or appearance is important, tig it or get someone to tig it for you... and I'd definately go w/ convincing the mrs. that you NEED to own a tig.



jm

 

[Blackcloud]

Pete- don't waste your time or money on AL rods,they aren't worth the package they are wrapped in. Poor quality and crappy penatration are all you will get (besides welds that look like bird droppings). If you can find a good welder to repair the brackets,then go for it,if not,then replace the brackets. Most "welders" do more harm than good.

 

[Extreme1]

Hmmmm... .



I found out about these rods a year or so ago from a guy I used to be a welder with before we got promoted. He showed me a sample he did and we were both impressed by the ability to produce a decent weld. (Not his ability, the rod's).



It might be worth a try to do it yourself. Worst case, you grind the mess off and get it done. Wire feed is also an option but you need a spool gun to do it best (aluminum wire doesn't like to get pushed down the lead for steel, it's too far). If you clean up the area you need done a weld shop shouldn't charge too much to wirefeed it. TIG get expesive because of the time and skill invloved.

 

[bighammer]

Thanks for the replies. They are at a local welding shop getting a pro's touch. I might buy a pack sometime just to practice with. That's sort of how I did the stainless. I boughtthe rods then I needed a repair on my sailboat. (bow pulpit rail) I got some scrap and ran afew beads untill I felt confident I could do good welds with it. Then I proceeded to completely toast the part on my boat OK, I had plenty of length and had to recut a couple times. I finally got it and you almost can't even see it.

 

[Agades]

you could convert your stick welder to a tig welder by attaching a high frequency box



(poor mans tig machine)



but 200 amps really aint enough for the average aluminum tig weld (over 1/8" thick material)

 

[HoleshotHolset]

How about converting a TIG machine to MIG?



I already have a kickbutt power supply with gas capability.....



Agades: Couldn't he get away cheap with a TIG torch and a regulator and SCRATCH-tart the tungsten, instead of using HF? :-laf



Matt

 

[Agades]

he probably could but you need the high freq to keep the arc stable on AC (aluminum and magnesium welding)



otherwise the arc wanders on AC



put it this way "it would bite the big one"



scratch start works just fine on DC ( welding ferrous metals)



to convert a tig or stick (all tig machines are stick machines with a little extra control) machine to mig, you would need a "voltage sensing feeder"



it works for the non critical weld (not X-ray quality)



works best with gasless wire



works like a wire feed but you have to play with arc length to get it to work ( combination of wire and stick welding)

 

[HoleshotHolset]

I have never done any MIG work... . but I'd like to.....



Stick welding with my TIG box is a blast..... I had all sorts of fun last weekend with some old 7014.



So... . all I need is a voltage sensitive feeder? Why would this be so much less desireable than a completely separate MIG machine?



One downside to this that I can see is the fact that if my TIG power supply eats it... . then I'm dead in the water. If I had a separate MIG setup... . then I could at least MIG and wait to fix the TIG.



Matt

 

[Agades]

mig machines are designed to control voltage and keep the voltage constant



voltage is what determines arc length and width and puddle fluidity

thats why when you mig weld your arc stays the same size



stick machines control amperage and you control voltage to a certain extent with arc length by how far away you keep the end of the rod



completely different power sources





there are some machines out there that are both mig and stick power sources.

they are actually two machines under one cover and you pay $$$$$$ for them

 

[Eric Kahn]

I am lazy and want a MIG welder, I can not afford a TIG welder which is what I really want, pretty welds even though they take lots of time

 

[Agades]

and a lot better quality too

Ive said it b4 and I will say it again



"wire feed is fer p%^^y's"

 

[HoleshotHolset]

I agree with Agades... .



Ain't nothing like a TIG.



It would be nice to have a MIG setup - just to fool with.



Okay - so I won't try to add a spoolgun to my TIG - it ain't gonna work that well, if at all.



Matt