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Originally Posted by KenWittlief
Aluminum is normally welded with a MIG welder using an inhert gas. This is a type of arc welder that feeds wire from the center of a handle. It is also connected to a cylinder of argon or carbon dioxide. As you weld the gas flows out over the weld in progress, keeping it in an envelope of the inhert gas. Since no oxygen is present, the alum does not oxidize into dust.
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I believe the preferred method of welding aluminum is with a TIG welder, unless it is a high volume production shop or really long beads. The problem with MIG welding aluminum is feeding the wire. It is very soft and tends to bunch up. If you keep the gun hose totally straight, it may work. When MIG welding aluminum, a spoolgun is the weapon of choice. This puts the wire right on the gun so it has a very short distance to feed. Unfortunately spoolguns are usually many hundreds of dollars.
Aluminum is usually welded with 100% Argon shielding gas.
The nice thing about stick welders is that you get the most power for your dollar, and you don't need to worry about wire speed and shielding gas and that sort of thing. You will have to chip off slag though. It is possible to make some really nice welds using a stick welder, but it takes practice. Vertical and overhead welding is definitely much easier with a MIG.
For stick (arc) welding aluminum, I know they make the rods, but I haven't heard any stories from anyone who's used them. If you try it out, be sure to let us know!
