First, I'll give the advice I have. Ditch tips and shop for Hobart tips. I had a terrible time with sticky wire during aluminum. Hobart tips didn't stick. Then spray WD-40 on the aluminum to get it ready to saw. Aluminum rubbers stick to saw teeth, so spray. Clean the aluminum to perfection with a stainless steel brush. Buy a large bottle of argon. This welder eats argon. Forget everything you knew about steel welding. The aluminum will remain silvery and melt, or the underside will sag from too much heat. Use the horseshoe pattern by sliding the wire through. Don't loaf around for too long if you're being welded. . The puddle is very difficult to see, so plan a second pass for better penetration of the structure's welds. The chart shows the recommended speed and temperature. Start with it and experiment. A few tweaks have been made to this weapon to keep the wire from going astray, but overall it's great. I bought a broken aluminum perch boat and rebuilt it with this welder. The steel wire side has good penetration and I am satisfied. I used 4 pounds of aluminum as a result. Two weeks ago I thought about returning it. Plugging in the wire took me hours. Good advice made him really enthusiastic. I think my aluminum welds look ok. I don't just camp, I advertise that I will weld aluminum to people. The local gets $150 an hour for aluminum. I have $120 an hour. By the way, I learned what WD-40 is on the last day of welding. I used to waste 5 Milwaukee Torch saw blades.
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