Welding Tips and Tricks

I have a lot of experience welding carbon steel, but his is the first time I have welded aluminum.

I've been practicing on 1/8 plate.

For starters, it smokes a lot. I'm surprised my neighbors didn't call the fire department.

When I use the settings in the table on the machine the weld is cold and doesn't fuse to base metal until after a couple inches then it wants burn through, And it smokes the same amount the entire time.

I have tried changing wire feed speed and voltage, if I go below the suggested settings then it never really fuses to the base material at all, if go above the suggested settings then it wants to burn though in a few seconds.

The power source and spool gun are new. I have welded carbon steel with solid .024" wire and this power source and the MIG gun that came with it, and it welds as to be expected.

I am using 100% argon, thats what the label on the cylinder says it is. Cylinder are leased from local welding supplier.

I am using the spool gun on DCEP

I am using ER5356 wire .030"

Gas flow is set to 30 CFH while welding.

I have taken the gun apart and checked for gas leaks or obstructions and cannot find anything obvious wrong with the gun.

THe amount of smoke it produces makes me think it isn't getting any shielding gas what so ever. The stinger is fully inserted into machine I've checked that twice.

Any suggestions would be greatly appreciated.

Aluminum MIG smokes. Get used to it. A push is far better than a pull with AL MIG. Contact distance matters too, and try to keep no more than a 10* angle away with your gun. Too flat an a push angle and you’re losing the shielding gas.

A little preheat helps too to get the first inch burned in. Or, a few healthy tacks to put some heat in the part.