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  1. #1
    Join Date
    Feb 2010
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    Default Pulse MIG for me?

    Hi, I've got a AC TIG and a standard MIG at the moment. Having spent another day on a boat fitout project I'm wondering about the benefits of a pulse MIG machine for thin aluminium. I've only got access to 240v 15Amp. Haven't got a firm budget, but would like to keep it sub $2000.
    I'd like to hear from anyone who does a fair bit of aluminium with MIG and opinions on whether the extra investment for a pulse MIG is worth it.
    Thanks
    - Mick

  2. #2
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    Sep 2010
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    Lebrina
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    Quote Originally Posted by WelderMick View Post
    Hi, I've got a AC TIG and a standard MIG at the moment. Having spent another day on a boat fitout project I'm wondering about the benefits of a pulse MIG machine for thin aluminium. I've only got access to 240v 15Amp. Haven't got a firm budget, but would like to keep it sub $2000.
    I'd like to hear from anyone who does a fair bit of aluminium with MIG and opinions on whether the extra investment for a pulse MIG is worth it.
    Thanks
    - Mick
    I can certainly offer up an opinion on this one.
    Pulse mig on Aluminium is the ducks guts but you will never equal the weld appearance of TIG. I cannot comment with real world experience of a single phase Pulse Mig as all units I have used have been three phase machines, but I can't see why a decent single phase machine on a good supply couldn't work as well, albeit at a reduced amperage level.
    While pulse offers great advantages with all aluminium thicknesses, it really stands out in the sub 3mm areas. 1.2mm wire will reach down to 2 or even 1.6mm thickness with little difficulty. The machines I have used most are a Eutectic 270 (actually a Fronius 2700) and my own CIG Transpulse 350. The Eutectic/Fronius machine was a much newer machine, but frankly the Transpulse doesn't give any ground on new material and absolutely kills the newer machine on old, contaminated aluminium, an area where the pulse process seemed quite inferior when using the Fronius machine.
    I would not rely on the pulse mig or any mig process to seal a tank or hull as well as a tig will.
    To sum up, pulse mig on aluminium opens up a whole new range of possibilities and will allow you to save time by welding materials that once were the territory of the much slower tig process, however if your material is above 2.5 or 3mm. a standard mig will possibly beat your times for performing the same task.
    I think your $2000 limit may present a few difficulties as there I haven't seen too many machines at that price point that I would trust. I think Token Tools have one at around the $1800 mark. You will also need a quality 15A supply if you want any degree of success. If you do a lot of boat work, a machine with a separate wire feeder would be a distinct advantage too.
    A couple of observations that I have made concerning pulse migs welding aluminium are that they seem to be harder on contact tips than a straight mig, but this isn't really much of an issue overall. Secondly they absolutely hate poor gun and liner maintenance, in fact they will protest quite noticeably if wire feed is not consistent.
    My final though is that I saw sufficient benefit in the process that I bought one, if that counts for anything.

  3. #3
    Join Date
    Feb 2010
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    Ballina, NSW
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    Default

    Thanks Karl,
    I found the tokentools and everlast ones pretty quickly, but not sure if there's others around. I'm not expecting the world for <$2K, but I couldn't justify more. You mentioned 3mm as a threshold. What got me on this track is that I've been welding on a lot of strengthener plates and brackets onto a 'plank' boat construction. The plates being 6mm and the plank is basically the same as scaffold plank with section thickness varying 2-3mm. The planks are to remain water tight in some hard to get at places, so every weld with the mig needs more than a bit of care.
    So with the pulse MIG - does the wire feed vary with each pulse? Is that why it's harder on liners etc.? How does pulse go with spool guns? I'd love a separate suspended wire feeder, but I doubt it'll fit the $.
    4 sleeps to end of tradie's Christmas.
    - Mick

  4. #4
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    I only mentioned 3mm as a point below whic pulse really begins to shine, but pulse is equally happy on 20mm material, provided you have a powerful enough machine. One big plus that I neglected to mention earlier is that pulse migs will recover from a blow through much better than a straight mig as well as handle imperfect fit up with ease. Liners do not wear more with the pulse process, although I find tips do, but interrupted wire feed plays havoc with the pulse process and the machines seem to forget where they are a bit if experiencing intermittent feed.
    You will find that in the application you describe, pulse will be in its element welding differing thicknesses.
    The question that only you can answer is if you have enough work and the improvement great enough to be worth $2000.

  5. #5
    Join Date
    Feb 2010
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    Ballina, NSW
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    Default

    Quote Originally Posted by Karl Robbers View Post
    ... to be worth $2000.
    I'm pretty good at making myself believe that I need new toys.
    Regarding tips, I usually end up stuffing them with burn backs long before they wear out!

  6. #6
    Join Date
    Dec 2013
    Location
    San Antonio, Texas, USA
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    17

    Default

    You may consider the Lincoln 210MP. I've been thinking about buying one for some time as a more portable supplement to my c300. I can't tell from the information available on-line whether or not it does pulse-MIG but the spec's cover aluminum in the range you're working with. The package with the spool gun runs around US$1500.
    The stone age didn't end because the cavemen ran out of stones...

  7. #7
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    The Lincoln 210MP is a cool little welder that seems to get good reviews but unfortunately it is not a pulse capable machine.

  8. #8
    Join Date
    May 2013
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    Gracemere
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    Default

    Hey Mick,

    Looking at selling mine if your still in the market. $2000 for the lot but you have to pick it up.

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