You're right. TIG isn't cheap but like a lot of the guys said, it's the way to go for aluminum or S/S. I've heard some good things about the hand spool for aluminum on a MIG unit, too. Also as an option to argon, I think (but make sure) that you can use CO2 as shielding gas and it's not quite the expense of argon but like I said, check first. Additionally, I've been trying to find out if an inverter can be used on a stick welder in -DC to run a TIG rig, one of the reasons I bought a stick in the first place. Miller doesn't want to answer that question so far. There may be more to it than I thought, but, ..... Best of luck in your pursuits

I don't know how well they work, but you can get 120 volt migs that have the option of adding a gas kit.  I think Lincoln is one make that has the optional gas kit.

Update -
My stick welder can work on 110 also (luckily, as someone stole my 50' 220v cord) but takes practice.
Also my mask with the auto darkening needs batteries more often than 10 yrs. I see spots !
Not much penetration with 110v but welded bumper back on sons 4 X 4 after a trail driving mishap.
Have used the alumaweld sticks and they work OK if you have a hot enough flame. Propane is not hot enough for most things. MAPP gas?
Have not seen BTU/temp ratings on any little torches.
Oxy/Acetelene tanks are $300 and I have the regulators and torches. Not the money at this time.
Randy

Grouch, CO2 is used for steel MIG welding. You have to use Argon for aluminum

Randy,
  I see where you said you were going to stay with the stick welder. You said you were looking at a mig for your shop & then asked about alum. Well a mig can be very beneficial in a shop as it can be used with solid wire, innershield & also stainless steel. Enough has been said about the alum welding so won't deal with that. In welding stainless you need a tri mix for the mig. You can purchase a small bottle so it won't cost you an arm & leg. I use wire most of the time & then have a Lincoln 300-300 for alum & also have a portable on my truck for field work. The mig if it is the right size can handle a wide assortment of material thickenss. I have a 250 & weld from 18 ga. to 1/2 inch & use solid wire. I have been in business for 33 years & do a wide variety of work from structural steel to farm equipment repaiir & fab. Don't give up on a mig just because it isn't the easiest to do alum with.

For information. Lincoln migs come with the gas regulator & are set up with the connections for gas. The 120 volt welder has enough power to weld 1/4 material & I have welded 3/8 with multiple pass.  That is if you are purchasing a new welder. The used ones should have the gagues with it. Miller also has a good machine but the foreign welders are not as well built as Lincoln & Miller.

unless you really have the time and money to invest in learning how to use TIG, id stick with MIG is much easyer for someone just learning aluminum. everyone has already said keep it clean, and it cant be stressed enough, cleaner the better. but also be aware alum transfers heat very quickly, so if you lay a weld the entire piece of alum will get very hot not just around the weld. good luck

Guys this is great info you have posted here, I love it. I have a MIG welder and I just did a lusia crown and have not have the money to get the gas system, But the instruction says I can weld aluminium BUT I have to use gas. You guys have given me a ton of info so I thank you!
Yours
Rbs

If you are into welding and/or cutting metals ov various different types , I would suggest that you check out the Multiplas 3500. Just google multiplas.


Wolf

Wow randy, It's been over a year since your original post on this topic. I have to agree that unless you plan to hire out to make a profit, getting a set-up for aluminum welding is too expensive for most of us. My last 24 years of welding was almost exclusively welding aluminum or Stainless steel. MIG welding And TIG welding and Stick welding on Stainless Steel. I've been retired now for about 6 years.

Some info.......................


http://youtu.be/V_MiGrL9350

Nice video's scooter. Good information !

Can't beat Miller................

hi randy,  you may also want to check with a welding supply store because they used to make an aluminum stick rod years ago and im sure they still do.  i used to use it  to repair wheel line sprinkler systems on my father in laws farm and it held up good against a lot of water pressure

Like this............

Hi folks, I'm back.
Got some of that alum rod from the local Ace hardware store a while back.
Some guy many years ago cam into shop I was working at and I welded a couple pop cans together with it.
Don't remember the prep but guess it was very clean as you guys talk about that.
Just didn't have the heat capabilities as used an oxy/acetelene torch back then.
Now have a little torch from HF that will do 2000 F it says.
That should be enough I think.
Used a TIG and a MIG before but forgot. Hobart/Miller etc. I cannot afford.
One of them had a seperate stick from the welded like oxy/ac braising.

Welding .125" 6061 , welds maybe 12" .
Wonder what kind of flux? Or is it built into the rod?

BTW my old stick welder helmet was given to a charity and I got one of those see through things and it works great!

Randy

Randy,

I have used something similar to what you found and it was called LUMIWELD. How had to have a SS brush and toll to prepare the surface first. The flux was in the LUMIWELD. I had a Jeweler's torch and was able to weld an aluminum valve cover back together. It takes some practice but the stuff really works.