Aluminum MIG Welding Settings Chart and Guide

Why would anyone want to use MIG welding? Well for one, this type of welding suits various metals including aluminum. Moreover, it comes as a cheap activity to pursue.

As an amateur welder, you can try MIG welding with aluminum. But before you can get the best results, it would help if you used a guide. Luckily, this post has a chart that can show you the best settings for your aluminum projects.

Aluminum MIG Welding Settings Chart

Here is a chart 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.

Below is a chart for the wire speed and voltage speed settings required for MIG aluminum welding. But before using these settings, ensure that you have a decent understanding of aluminum and the required amperage.

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

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

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

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

Aluminium MIG Welding Settings for Aluminium 4043

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

As you work with an 0.30-diameter aluminum size, it would help if you applied the ideal MIG welder settings.  With this in mind, an aluminum sample with 0.125″ thickness requires volt /speed settings of 20 and 300 respectively.

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

As you work with this wire size, you will have to use different settings for different sizes. For instance, 0.75 “aluminum requires volt and speed settings of 18 and 235. As for 0.125 “aluminum, leave the volt and speed settings on 22 and 395 respectively. 

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

Does your project involve a 0.030 wire with 240-volt input? If yes, use a volt/speed setting of 18/350 for 0.75 aluminum. As for 0.375″ aluminum, select a volt and speed setting of 28 and 530. 

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

If you work with this type of sample, you will need different settings for different levels of thickness. For instance, a volt/speed setting of 22/395 works with 0.125 thickness while 0.25 thickness uses 26/485. 

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.

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. 

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 or the center. Also, ensure that the wire does not drop from your grasp. 

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.