Aluminum MIG Welding Settings Chart

For most welders, MIG welding is ideal for several types of metal including aluminum. After all, this type of welding works great with such materials. Besides, the welding process will not wipe out their bank accounts.

Are you an amateur welder that wants to try MIG welding with aluminum? If yes, you will need a guide that will offer the best settings for working with this material.

aluminum mig welding settings

In this post, we have listed several settings for aluminum MIG Welding. So if you need a guide for working with aluminum, scroll through this article and choose the ideal settings for your aluminum project. As expected, these figures will offer the best results for such tasks.

Aluminum MIG Welding Settings Charts

Here are charts showing the wire speed and voltage speed settings required for MIG aluminum welding. But before using these values, we suggest that you have a decent understanding of your preferred metal. Also, consider the amperage settings and the task at hand.

Aluminum MIG Welding Settings Chart for 0.30 Wire Size (120-volt input) ( Solid Wire 4043)

Material Polarity Shielding

Gas

Volt/Speed Settings for .035 Volt/Speed Settings for .049 Volt/Speed Settings for .075 Volt Setting for .125
Aluminium DECP 100% Ar 18/234 20/300

Aluminum MIG Welding Settings Chart for 0.35 Wire Size (120-volt input) ( Solid Wire 4043)

Material Polarity Shielding

Gas

Volt/Speed Settings for .035 Volt/Speed Settings for .049 Volt/Speed Settings for .075 Volt Setting for .125
Aluminium DECP 100% Ar 18/235 20/278

 

Aluminum MIG Welding Settings Chart for 0.30 Wire Size (240-volt input) ( Solid Wire 4043)

Material Polarity Shielding

Gas

Volt/Speed Settings for .035 “ Volt/Speed Settings for .049″ Volt/Speed Settings for .075″ Volt Setting for .125″ Volt

Setting for . 187″

 

Volt Setting for .25″ Volt Setting for .375″ Volt

Setting for. 5″

Aluminium DECP 100% Ar 18/350 22/395 24/440 26/485 28/530

 

Aluminum MIG Welding Settings Chart for 0.35 Wire Size (240-volt input) ( Solid Wire 4043)

Material Polarity Shielding

Gas

Volt/Speed Settings for .035 “ Volt/Speed Settings for .049″ Volt/Speed Settings for .075″ Volt Setting for .125″ Volt

Setting for . 187″

 

Volt Setting for .25″ Volt Setting for .375″
Aluminium DECP 100% Ar 18/350 22/395 24/440 26/485 28/530

 

Aluminium MIG Welding Settings for Aluminium 4043

Material  Used Wire Type and Polarity Setting Suggested Shielding Gases

 

20-30 cfh flow rate

Diameter of Wire  Voltage/ Wire Feed Setting for 0.60 inches

Aluminum

Voltage/ Wire Feed Setting for 0.105 inches

Aluminum

 

Aluminium Aluminium 4043 100% Argon 0.30 mm 3/90  5/90
Aluminium Aluminium 5356 100% Argon 0.30 mm 2/100 4/100

 

Aluminum MIG Welding Settings Chart for 0.30 Wire Size (120-volt input) (Solid Wire 4043)

If you are working with an 0.30 diameter aluminum wire size, you will have to get its ideal MIG welder settings for the thickness of your preferred aluminum sample. Let’s say you are working with an aluminum thickness of 0.75″, you will have to leave the volt and speed settings on 18 and 234 respectively.

Aluminum MIG Welding Settings Chart for 0.035 Wire Size (120-volt input) (Solid Wire 4043)

Even if you are an amateur welder, you can still work with a combo of 0.035/120v/ Aluminium Solid Wire. For instance, if you are using these conditions with 0.125″ aluminum, leave the volt and speed settings on 18 and 235. But if you work with about 0.125, stick with 22 and 395.

Aluminum MIG Welding Settings Chart for 0.030 Wire Size (240-volt input) (Solid Wire 4043)

Do you want to work with a 0.030″ wire size, 240-volt input, and aluminum solid wire 4043? If yes, then you should also get the best settings for these conditions. For instance, as you work with 0.75 ” worth of aluminum, stick with a setting of 18/350. Then for 0.125″ aluminum metal, allow the welder to stay at volt and speed settings of 22 and 395.

Aluminum MIG Welding Settings Chart for 0.035 Wire Size (240-volt input) ( Solid Wire 4043)

With a 240 volt input, you can work with varying thicknesses of aluminum. For example, as you are working with an 0.035 wire size, that volt setting, and 0.375 inches, leave the setting on 28/530.

Aluminium MIG Welding Settings for Aluminium 4043

If you are working with 0.60-inch Aluminium 4043, you can apply some MIG welding. Let’s say you are using 100% Argon and 0.30 diameter wire, leave the voltage setting at 3 while the wire feed stays at 90.

But if you work with 0.105″ of the same aluminum, leave the voltage setting on 5. Then adjust the wire feed to 90.

Aluminium MIG Welding Settings for Aluminium 5356

As you try to adjust the MIG tool for 0.60″ Aluminium 5356, set the MIG voltage to 2 and keep the wire feed on 100. But for 0.105″ aluminum, leave the voltage and wire speed on 4 and 100 respectively.

How many Amps Does it take to Weld Aluminium?

According to experts, a 1 amp of electricity is enough to work with every 0.001 inches of metal, especially under constant variables. However, factors such as the thickness of the material play a major role in deciding the amperage.

What Polarity Do I Use When MIG Welding Aluminium?

As you work with aluminum, you will have to set the feed welder to electrode positive polarity.  When it comes down to it, two thirds of the current is generated.

While you use this polarity, make sure the welder is switched to this setting.

Do You Push Or Pull when MIG Welding Aluminium?

If you are MIG welding aluminum, work with the forehand push direction. After all, this movement allows the shielding gas to cover the gas properly.

Aluminum MIG Welding Tips and Tricks

Are you looking for an easy way to get the best results for your Aluminum MIG Welding projects? If yes, here are some tips that can help you achieve your goal.

1. Use High-Quality Wire

Asides from having great welding skills, using high-quality wires can help with your work. Instead of using any wire, look for a brand that offers a smooth finish with a consistent cast and helix.

2. Handle the Spool Correctly

As you use the wire for your project, treat it with care. You can start by lifting the spool from the bottom of the center. Also, ensure that the wire does not drop from your grasp.

3. Use the Right Equipment

Choose contact tips that are designed for working with aluminum. After all, using the wrong tips can result in several errors.

Author

  • Danny Saunders

    Danny Saunders is a tech enthusiast. He enjoys getting his hands dirty with the features and settings of tech products and pushing them to their limits just to know how to get the best from them and how well they can endure "abuse" without breaking down. He shares his findings on this blog.