Aluminum MIG Welding Troubleshooting with Peter Zila

Troubleshooting welding issues is an important skill for welders, and recognizing when it's time to change the liner can help ensure optimal weld quality. In the scenario you mentioned, where the liner had drag and resulted in sooty welds, along with identifying a long arc length, here's some troubleshooting guidance:
Liner Condition: If the liner has drag or excessive wear, it can affect the wire feed and lead to inconsistent or poor-quality welds. Drag can occur due to accumulated debris, kinks, or excessive wear inside the liner. If you notice drag or resistance while feeding the wire, it's an indication that the liner needs to be replaced.
Sooty Welds: Sooty or dirty-looking welds can be caused by a variety of factors, including improper shielding gas flow, contaminated base material, or insufficient wire feeding. However, in this case, the drag in the liner could be a contributing factor. A worn or dirty liner can disrupt the smooth feeding of the wire, leading to erratic arc behavior and poor gas coverage, resulting in sooty welds.
Arc Length: A long arc length refers to the distance between the electrode (wire) and the workpiece. An excessively long arc can lead to a weak and unstable arc, increased spatter, and poor weld penetration. To address this issue, it's recommended to decrease the synergic voltage or adjust the welding parameters to achieve a shorter and more controlled arc length.
When troubleshooting welding issues, it's important to consider various factors that can impact weld quality, including equipment condition, settings, and technique. Regular maintenance, such as replacing worn liners, can help maintain consistent wire feeding and improve overall welding performance.
Although complete pictures of the welds would have provided additional context for troubleshooting, addressing the liner drag issue and adjusting the arc length are important steps to improve weld quality.

[@johnmacmillan627]

Thanks Peter, very informative.

[@graceespa]

Fantastic tutorial video. Thank you Peter for this. Looks like you're using .125 aluminum. What settings were you using for this? Thank you

[@billyn9580]

I had issues with my welder kept kinking at spool wheels. Changed a few contact tips and yep had to change my liner. I feel bad for any new person who has to trouble shoot what's wrong. Definitely takes time and practice. Happens to the best of us.

[@user-xw7iz4ky3m]

Very nice

[@JimsRobot]

Thanks for the video, very useful

[@usaweld]

You are welcome!

[@sskillie1]

I bought mine in April and still haven't had a chance to try it out yet😢 too busy.

[@LoranaSeecharran-si8hg]

I. Never. Seen. Anyone face. So. Close to the. Helmet you. Melting. The. Helmet. Baby 😂😂😂

[@cuskit]

I mean, what other company puts out this kind of awesome tutoring videos? This is great! One question - how often would you say you'd need to change the liner? For instance, once per 8" spool of aluminum? A dozen spools per liner? 25? Thanks, really enjoying these videos! mike

[@usaweld]

Unfortunately there is no set time as there are a lot of variables that play into how much the liner wears and tears. It really is based on the weld and when the wire is not feeding right.

[@billyn9580]

I store my welder in a job box with other welding supplies. I have a higher chance of bending or kinking my liner. Think of a long spring throughout the entire hose. If you didn't already know.

[@willhall7777]

I think I heard you say you don't like to use crappy wire. I didn't think name brand mattered.... Do you have a video about the wire you recommend? As far as alloy I use 4043 most the time.

[@usaweld]

Yes we do. We use Alcotec aluminum wire at HTP and that is all we sell. We have a video about it too.

[@usaweld]

th-cam.com/video/b6LpYaFwn_M/w-d-xo.html

[@3Beehivesto300]

How do you get the aluminum wire to move through a whip? It does not look like a pull gun.

[@usaweld]

We use a low drag liner and high quality aluminum wire. It is surprising what a difference it makes. Also our aluminum gun is sized to the system to make it run like this. This machine is made to run aluminum among other steels and alloys. It is awesome.

[@johnversluis3084]

what happen to HTP made in China now ?

[@leebatt7964]

God zilas a monster welder! See what I did there? God zila?

[@quatschohnesoe1549]

The smoke is very toxic.

[@georgeshotrodbarn2113]

Does this apply to steel wire too?

[@billyn9580]

Yes applies to MIG any wire. Other wire feed variable is make sure to use the right wheels. .025 .035 Flux or non-Flux. Using correct contact tip (size wire).

[@usaweld]

No

[@paulkurilecz4209]

Can't really run 4043 through a standard MIG gun. You are having feed problems. You are also getting flashback to the contact tip.

[@usaweld]

With a 26 MIG gun you can absolutely run 4043 and other aluminum wires. All with way more adjustments / parameters than a spool gun.

[@usaweld]

Yes, you are correct. You must change the liner at a minimum when switching to aluminum. With the ProPulse system, we use the 26 series gun set up for aluminum with a Teflon liner. I see what you mean about other manufacturers equipment being different. If you weld aluminum- you have got to try a Pro Pulse- it gives you a unique way to join metals.

[@paulkurilecz4209]

@@usaweld I recently purchased a dedicated TIG welder and your dedicated TIG Welder was in the running. I think that you have very fine products, but what concerns me, and correct me if I am mistaken, is that only a 30 day warranty period is provided. For the expenditure that is being made I consider this to be a shortcoming. When I am looking at acquiring another welder, i will definitely consider your products.

[@usaweld]

@@paulkurilecz4209 30 day Money Back guarantee. 3 year warranty on most machines. We take care of our customers.

[@paulkurilecz4209]

@@usaweld
Thank you for the correction. When I need another welder, I will definitely consider this machine again. Perhaps I was just confused.
PS: I purchased a spool gun for my current MIG welder and I like it very much. A little bulky though.

[@nopatience1417]

Never seen anyones face so close to the weld seems like you would be melting your helmet

[@RoyTelling]

I have been welding for 45 years and I can say, he knows what he is talking about
BUT he is a bad teacher! No way should he be showing someone how to weld without gloves on.

[@Migman2020]

what a useless teacher.. on pulse mig you adjust the arc length through the machine.. not physically.