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Ali-MIG 5000-series Al-Mg - wire dias 1.2mm vs 1.6mm

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  Ali-MIG 5000-series Al-Mg - wire dias 1.2mm vs 1.6mm Richard Smith <null@void.com> - 2026-06-03 06:43 +0100
    Re: Ali-MIG 5000-series Al-Mg - wire dias 1.2mm vs 1.6mm Richard Smith <null@void.com> - 2026-06-03 18:46 +0100

#543360 — Ali-MIG 5000-series Al-Mg - wire dias 1.2mm vs 1.6mm

I've gone for an Ali-MIG (Aluminum-GMAW) welding machine.

Lincoln Foundation book says all 1/16" = 1.6mm (apart from bigger for
bigger size).
I have only used 1.2mm wire - 5356 - some 5183.

At thicknesses of Ali plate of like 10mm and 12mm, reckon about
14m/min of 1.2mm wire.
(/ 14e3 25.4) ;; 551.1811023622048 ;; inch
So is 551ipm

By area ratio - which is exact guidance for steel - would be for 1.6mm
wire
(/ (* 14 9) 16e0) ;; 7.875 ;; m/min
(/ 7.875e3 25.4) ;; 310.03937007874015 ;; 310ipm

AI searched for me - it says
* 1.2mm more penetrative
* 1.6mm is softer more spread-out arc

With 1.2mm wire I wondered if fillet corner fusion was too much (!).
On T-fillet 10mm thickness definitely and Al-Mg (5000-series),
* edges plasma-cut
* plate much abraded (it was a recovered floor checker-plate)
* which I wire-brushed with a steel brush (no stainless wire brush)
There was quite a swirl of solid detritus circulating around at the
leading edge of the weld-pool, and I got a sense I was slowing-down
the weld to let it float-out and ensure fusion.

I tentatively thought
* I run much quicker on clean plate
* I suspect the very penetrative arc was melting-out contaminants in
  the contact between the terminating plate and the continuous plate
  in greater quantity?

I can macro-etch marine-grade Ali, to inspect the outcome.
I do want to avoid equipping up with MIG-torch / GMAW-gun which I
don't use.
Hence - anyone know the arguments on this and can advise?

I did break a weld in the wrong place and it took seemingly too little
effort.  I suspect the slowed run-rate gives coarser structure which
is less strong (?).
I suspect I need to weld fast(er).
I like the idea of uniform penetration across the weld legs, and
running fast...

Anyone tell me if I can weld Al-Si 4000-series with a standard "push"
wire-feeder if the wire is 1.6m / 1/16" ?
With slippery liner - PTFE or HDPE? (only met HDPE).
I have never MIG'ed 4000-series before.

Regards, Rich S

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#543363

Richard Smith <null@void.com> writes:

> I've gone for an Ali-MIG (Aluminum-GMAW) welding machine.
>
> Lincoln Foundation book says all 1/16" = 1.6mm (apart from bigger for
> bigger size).
> I have only used 1.2mm wire - 5356 - some 5183.
>
> At thicknesses of Ali plate of like 10mm and 12mm, reckon about
> 14m/min of 1.2mm wire.
> (/ 14e3 25.4) ;; 551.1811023622048 ;; inch
> So is 551ipm
>
> By area ratio - which is exact guidance for steel - would be for 1.6mm
> wire
> (/ (* 14 9) 16e0) ;; 7.875 ;; m/min
> (/ 7.875e3 25.4) ;; 310.03937007874015 ;; 310ipm
>
> AI searched for me - it says
> * 1.2mm more penetrative
> * 1.6mm is softer more spread-out arc
>
> With 1.2mm wire I wondered if fillet corner fusion was too much (!).
> On T-fillet 10mm thickness definitely and Al-Mg (5000-series),
> * edges plasma-cut
> * plate much abraded (it was a recovered floor checker-plate)
> * which I wire-brushed with a steel brush (no stainless wire brush)
> There was quite a swirl of solid detritus circulating around at the
> leading edge of the weld-pool, and I got a sense I was slowing-down
> the weld to let it float-out and ensure fusion.
>
> I tentatively thought
> * I run much quicker on clean plate
> * I suspect the very penetrative arc was melting-out contaminants in
>   the contact between the terminating plate and the continuous plate
>   in greater quantity?
>
> I can macro-etch marine-grade Ali, to inspect the outcome.
> I do want to avoid equipping up with MIG-torch / GMAW-gun which I
> don't use.
> Hence - anyone know the arguments on this and can advise?
>
> I did break a weld in the wrong place and it took seemingly too little
> effort.  I suspect the slowed run-rate gives coarser structure which
> is less strong (?).
> I suspect I need to weld fast(er).
> I like the idea of uniform penetration across the weld legs, and
> running fast...
>
> Anyone tell me if I can weld Al-Si 4000-series with a standard "push"
> wire-feeder if the wire is 1.6m / 1/16" ?
> With slippery liner - PTFE or HDPE? (only met HDPE).
> I have never MIG'ed 4000-series before.
>
> Regards, Rich S

I've gone for 1.6mm / 1/16th-inch - for the
* gun / torch size (300A)
* liner (PTFE)
* contactor-tip (for ali.)
* feed-rolls - U-groove for ali.

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