Welding Aluminum

[NPloysa]

I have never welded aluminum.



I want to make some frames for banners here at work. They are 6x12 feet. The banner company wants $2190. 00 each. I was thinking I could do it out of steel, but boss says it will rust too easily and would like aluminum. The reason for this is to make some cash from it, and I do enjoy metalworking.



I would have to rent a Tig since all I have is a Mig. Is aluminum more or less costly than mild steel? I need 240 feet total. I can't really explain the final shape for these but measured it out to 120 feet each which includes extra for mistakes, and these are 20 foot sticks.



I have the other welding, grinding, cutting, metal working equipment. I have welded with a Tig, but just a very small aluminum box, years ago.



I will check steel and aluminum prices, Tig rental prices, etc. Is there a way to make it out of steel and prevent rust?



Thanks!



Nick

 

[SRadke]

Aluminum is much more expensive than steel.



My best advice for you is to check with your local welding shop about getting a small spool gun for your mig welder and a bottle of argon. When set up properly they work pretty well and it'll be much faster than TIGing the whole thing. They won't mak teh pretty welds that a tig will but if you don't have much tig experience that isn't going to happen anyhow.



-Scott

 

[cap-n-cray]

Have you thought of stainless steel? You could weld it with your mig with ss wire and argon, reverse polarity. I like SS.



Cary

 

[HoleshotHolset]

Don't get me wrong - I LOVE TIG... used to have a Miller Syncrowave 180SD digital. :{



However, if you're doing production work - Do like Scott said... get a spoolgun. Traditional MIG - where the spool lives in the machine - has a tendency to bind up in the line since the aluminum wire bends easily. If you have a spoolgun - the path the wire has to go through is very minimal and it shouldn't bind up at all. Since you're welding big signs - the bigger spoolgun shouldn't get in your way.



I'd also recommend that you need to find a big arsed bottle of CO2 and argon mixed 50/50. The CO2 will help a lot when welding aluminum...



Matt

 

[Turbo1Ton]

I'd also recommend that you need to find a big arsed bottle of CO2 and argon mixed 50/50. The CO2 will help a lot when welding aluminum...



Matt

I always thought that you welded aluminum with straight Argon. If you use any amount of CO2 won't it oxidize and give a cruddy weld?

 

[Chris Bultman]

You do use straight argon when welding aluminum. Make sure your parts are VERY clean, preferably use a stainless wire brush that has not been contaminated with anything. The cleaner it is the better it will weld.



Chris

 

[HoleshotHolset]

My bad, dudes - I'm mistaken about the CO2/Ar mix and welding aluminum. I must have heard that somewhere and ended up repeating bad info. Not cool.



Matt

 

[CWebster]

If you have a short enough lead(10-15') you can get away with just swapping the wire and gas (and the liner if its been on there a while/kinked), maybe go to the next size tip and be conscious of the straightness of your lead..... all depends on how many welds your gonna lay, position, etc. . We've done this many times when somehting HAD to go out the door RIGHT NOW and a repair/missed weld/ etc. had to be taken care of. It's definitely down and dirty, but it's easy on cash flow and saves a lot of running around. My $. 02

 

[CWebster]

You could also use mechanical connections and make it real easy on yourself. I know that awning companies around here use similar products.



http://www.wagnercompanies.com/site/Viewer.aspx?iid=2851&mname=Article&rpid=529



Chris