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How do i MIG/GMAW weld my cracked thin aluminum irrigation pipes?

During the winter sometimes there is water left in them and they freeze and crack open. The aluminum is so thin that when i try to mig weld it, it just eats right through it. I can adjust the settings such that it doesnt but the metal is just dripping slowly onto the pipe. This is a very sloppy way to do it, i know there must be a better way.
I use .30 aluminum wire fed through the spool gun, as well as using 100% argon. I also keep the end of the wire clipped off when starting the pool, but have the same trouble listed above

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6 Responses to “How do i MIG/GMAW weld my cracked thin aluminum irrigation pipes?”

  • bob_e_dawg:
    May 8, 2010 at 4:28 pm

    It isn’t possible to weld aluminium correctly using MIG TIG or MAW. The only way is stick using special rods. Thin aluminium !! ha waste of time. Try using gaffa tape for a decent seal.

  • ak:
    May 8, 2010 at 4:40 pm

    TIG might help on thin aluminum but heat is the problem as you pointed out. Light gauge aluminum just won’t hold the heat. Plus, TIG is expensive. On the other hand, they do weld aluminum lawn chairs and patio furniture together…

    Call a few local welding shops and see what they recommend.

    Sometimes an ugly weld that doesn’t leak is good enough.

  • reba4glass@sbcglobal.net:
    May 8, 2010 at 5:08 pm

    TIG welding is the way to go call some local welding shops they will help you out

  • thinkharderchri:
    May 8, 2010 at 6:00 pm

    Are you using the proper wire in your mig to repair the aluminum? The only way to properly weld aluminum is using aluminum wire and 100% Argon as a shielding gas. This is usually best accomplished using a spool gun that you can attach to a high frequency output on some mig welders.

    But if that is not an option you can use an aluminum spool of wire in a regular mig but you waste a lot of wire pushing it so far through the whip to the gun, also the aluminum wire is very fragile and subject to easy kinking in the line. A quick tip: always break off the glob of aluminum at the end of the wire each time before resuming welding, it take far less amps to make the weld puddle start and will not kink the wire or burn through as easily.

    Additional Info:

    If you will visit this website it might have some additional tips that may assist you.

    http://www.lincolnelectric.com/knowledge/articles/content/alum.asp

  • chrisItux:
    May 8, 2010 at 6:33 pm

    there is an easy way –get a block of aluminum and start welding on that and quickly transfer for a moment to thinner stuff and switch back to the block to let the thin stuff to cool off before switching back to weld a bit more and switch off back to the block this is the method i used to weld the thin stuff and most times it works and make sure you are using spool gun for this they are designed for aluminum welding — low setting but moderate wire speed

  • Don:
    May 8, 2010 at 6:50 pm

    Part of my job is welding aluminium irrigation pipes. I Have successfully used mig, but it is a little tricky. Heat it the main problem, either to much or not enough. Now I only use TIG as it localises the heat gives good penetration and beautiful welds. If you can Oxy weld Tig is basically the same. Just make sure the area to be joined has been buffed and cleaned. Preparation of the weld area is just as important as the welding.

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