Aluminum Welding Guide

Purchase contact tips with bore sizes that are 10% larger than the electrode diameter.

Warning: A 3/64” (0.047”) diameter aluminum electrode is a different size than 0.045” diameter steel electrode and takes a different size tip. For instance a 0.052” diameter tip is the correct size for 3/64” aluminum wire. Contact tips for steel are stamped 0.045” and are not to be used with an aluminum electrode. Purchase contact tips that have polished bores free from burrs on the inlet and exit ends.

• If the contact tip that you are using does have inlet and exit burrs, remove the burrs and polish the bore with a circular wire file.
• Recess the tip 1/8” to 1/4” into the gas cup to promote tip cooling and to reduce spatter and oxide accumulation that acts like burrs at the end of the contact tip.
• Replace all metallic wire guides with non-metallic material. Ask equipment manufacturers for their non-metallic guide kits.