The main advantage of using a spool gun is improving preciseness while feeding wire. But why do you need a spool gun to weld aluminum?
Some people think it is compulsory, and some say optional.
You should use spool gun to reduce the travel distance of softer aluminum mig wire for aluminum welding. That in turn can decrease the risk of wire jamming.
Also the gun ensures stable arc, deeper penetration, cost effective welding. For quick and clean welding on aluminum you should choose one.
Lets start with a basic question-
Do You Must Use A Spool Gun To Mig Weld Aluminum?
It is not mandatory to use a spool gun for welding aluminum. You can use several alternative methods for welding aluminum.
For example, A normal MIG welder gun is capable of welding aluminum effectively if you have the essential welding skills. Some people found better result using mig torch with Teflon liners into it.
Actually it depends on the application and project you are working on. For heavy aluminum applications, spool gun provide better results, for small applications, mig gun is enough.
But remember, aluminum is a pretty sensitive & soft metal. You must have complete knowledge of this metal’s electrical and thermal conductivity.
Otherwise, you won’t get precise results and may even ruin the entire project.
Why Should You Use A Spool Gun To Weld Aluminum?
It is common to twist a metal like aluminum out of shape within a blink. After all, it is a pretty delicate material. Besides, the oxidization process swiftly begins once you start the welding session.
Which may lead to a lot of problems in the welding aluminum. It gives a proper backup by feeding wire to prevent untidy and dirty welding.
The feeder is located at the top of the gun. It feeds a right amount of wire at the correct wire feed speed.
So if you use this welding gear, you can get better penetration and strong weld on aluminum than other methods.
Benefits Of Using Spool Gun In Welding Aluminum
Use of a spool torch gives the following noteworthy advantages.
01. A Stable Arc
You know why arc stability is vital for welding? It allows you to maintain a similar shape of droplets and minimal spatter.
A spool gun will help you keep a stable arc with a constant length. You won’t have to worry about the deposition rate and fusion too.
02. Quicker & Smoother Welding
Remember, steel and aluminum are not the same. If you have not welded any Aluminum in the past, the challenge is vital. A spool gun can save you from the unwanted tangling of the welding wire of the wire feeder.
You will save a decent amount of time by using one.
03. Neat & Clean Welding
Inexperienced welders who have not used any spool are likely to bulge off weld metal. You may see over-melting problems while welding aluminum. It will cause a consequential overflow on top of the metal.
A functional and compatible spool torch can make welding aluminum more straightforward.
Overall, it creates neat and clean welding. The welding quality will be better too.
04. A Cost-Effectiveness
A spool gun can minimize your welding cost by up to 30% to 40%. You make minimal mistakes. Making fewer errors means using fewer resources.
As a result, you won’t have to buy additional items to finish the entire project.
How To Weld Aluminum With A Spool Gun?
One of the best approaches for welding aluminum is MIG welding.
Here are the steps to follow-
- Step: 01
Grab your gun and detach the canister cover and contact tip. Adding the right amount of aluminum wire inside the pistol grip-style gun is vital.
- Step: 02
Measure eight to ten inches of aluminum wire and fasten it using clips. Create a temporary joint using the wire inside the spool gun. Now, keep the aluminum cable spool in the canister of the gun and place the cover on it.
- Step: 03
Clamp the tensioner arm closed and do an appropriate tighten for it. Wire belts come in various sizes. Select a particular contact tip based on it.
Before adding the nozzle, securely keep the contact tip inside the spool gun. You are ready to go if you ensure a perfect installation of these two items.
- Step: 04
Adjust the Mig Welder Wire Feed Roller Tension to avoid unwanted strain or flattened problems. It should be neither too much nor too low.
Otherwise, the wire surface will be damaged. Your key aim should be to maintain a consistent and smooth speed to achieve the best quality weld.
- Step: 05
A delicate metal like aluminum is likely to form oxides. Keep the welding area free from oxides. Because they inhibit proper heat transfer and cause contamination within the weld joint.
Laser oxide removal is the best choice. But if you have a limited budget, you can use Acetone with a stainless-steel brush. This industrial solvent removes oxides and other items properly.
- Step: 06
A 10° to 15° angle is the best choice for wire welding. It ensures better penetration on thinner materials at the correct flow rate. Also it reduces the porosity. Use the angle for welding aluminum
- Step: 07
Excessive heat input is one of the common issues for burn-through weld defects. It happens when the torch nozzle gets contacted with the bottom base metal. So keep attention to the nozzle.
- Step: 08
Connect the spool gun with a bottle of argon gas from the positive base end. It works as a shielding gas. But, if you have a reasonable budget, use argon and helium mix. It ensures better penetration than using pure argon.
Tips For Using A Spool Gun To Weld Aluminum
- Use a push angle method in MIG aluminum welding when you use a spool gun. You can achieve a more aesthetically attractive bead.
- Initially, start with higher feed rates to ensure perfect contact between the weld puddle and the cable. But decrease it gradually once it becomes hot enough.
- Make sure sometimes to utilize the cutting tool to cut aluminum wires. It will prevent damaging the Contact tips
- It is a solid rule of thumb to use 14- to 18-gauge thickness of aluminum when using a MIG welder.
- Maintaining a perfect bending of the spool gun wire will ensure better quality feeding. Excessive bending will result in wire snagging or hang up
Can You Weld Aluminum Without Spool Gun?
Yes, you can weld aluminum without a spool gun. One of the best approaches is using a MIG welder to weld aluminum without a spool gun.
Yet, don’t expect to receive a steady, reliable wire feed unless you gain enough experience and welding skills.
Plus, it will be hard to achieve better penetration and consistent welding results.
Closing Thoughts
Spool tool makes your welding task more manageable and smoother. For aluminum using spool torch is the best way to ensure quality weld. Also it saves time and increases the life time of the machine and torch.
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