It may be new welder time, esab, kemppi, ewm, fronius

[Robbie260]

I recently had a play welding alu with my kemppi, i was quite impressed how well it did, and that was about 3mm checkerplate,
turned out looking good enough, but i was quite out of practice, not migged alu for years,
no issues with it feeding wire, but then again, its not that long a torch lead.
With some more practice im sure i could make it loo a bit better, but if looks aren't too important, its a hell of a lot quicker than tig!!

Cheers finy that's good to know have to admit the kemppi is still on my list.

Oh and regarding the Millers, was looking at them a few years back, about the same time as I was trialling the Cebora. Got put off by a few people saying reliability and backup was an issue but how true that was I am not sure, ended up going with another Phoenix and don't regret it one bit but obviously not what you are looking for.

Yeah have heard the same about miller's so why I'm not quite so keen on them my self. Have to admit i felt the Fronius claim sounded a bit marketing gimmicky. But have to see it to believe it.

I think I could manage with normal synegic mig I doubt I'd go under 3mm for the skin and could tig any little bits that did. Saw a cobra seemed a nice enough machine but must admit I wasn't convinced by the wire feed system.

 

[Hood]

I'd say your right about under 3mm not really working, and at only 200amps much above 3mm wont really be happening either, so not a huge window of usefulness, but handy for some things,
i was thinking things like repairs to ifor williams stock box floors etc

200Amps will get you 6mm easily with a Mig, I was surprised myself as all the years I had welded Aluminium with the Mig I had never had an ammeter so didn't really know. The R-Tech MTS255S was the first I had with the ammeter and even then I never really paid attention to the current as it was wire feed and volts as that were displayed when not welding. I did however do a load of tests with Mig, Pulse Mig, Double Pulse Mig and also Tig and when I paid attention I was surprised at how low the Mig current actually was.
Likely due to it all being on the positive where Tig is AC and thus MIG gets a lot more heat in for a given current than Tig can.

 

[finyuk2005]

Thats one thing about the kemppi, its a plastic 2 roller feed unit, but then again, it is only made to take 5kg spools,
I bought it because Kemppi seems to get a good name for reliability, and its pretty light weight, and also its meant to handle long extension cables and crappy generator power without blowing up,
im sure thats what killed my old parweld stick welder, so i replaced it with a kemppi stick

 

[finyuk2005]

200Amps will get you 6mm easily with a Mig, I was surprised myself as all the years I had welded Aluminium with the Mig I had never had an ammeter so didn't really know. The R-Tech MTS255S was the first I had with the ammeter and even then I never really paid attention to the current as it was wire feed and volts as that were displayed when not welding. I did however do a load of tests with Mig, Pulse Mig, Double Pulse Mig and also Tig and when I paid attention I was surprised at how low the Mig current actually was.
Likely due to it all being on the positive where Tig is AC and thus MIG gets a lot more heat in for a given current than Tig can.

ah right, i never tried any thicker, i was just going by what the synergic setting went up to on the kemppi!

 

[Robbie260]

Thats one thing about the kemppi, its a plastic 2 roller feed unit, but then again, it is only made to take 5kg spools,
I bought it because Kemppi seems to get a good name for reliability, and its pretty light weight, and also its meant to handle long extension cables and crappy generator power without blowing up,
im sure thats what killed my old parweld stick welder, so i replaced it with a kemppi stick

Have to admit there is this weird perception in the world that plastic is inferior to metal. If its been spec'd and made of a suitable quality plastic it should last as long as any metal component in appropriate circumstances.

 

[finyuk2005]

thats likely true enough, i certainly haven't had any problems so far!

 

[Hood]

Just did a bit of searching and found the thread, here are some relevant pics from it, I think it is 5mm I was using to test the various processes out.
The R-Tech weld on the first pic is not really a good test as it was right at the end of the plate but the pic below shows a better comparison.

 

[Robbie260]

Just did a bit of searching and found the thread, here are some relevant pics from it, I think it is 5mm I was using to test the various processes out.
The R-Tech weld on the first pic is not really a good test as it was right at the end of the plate but the pic below shows a better comparison.




View attachment 275461


View attachment 275462

Cheers that really is a useful and interesting comparison. The double pulse really dose seem to get good penitration. Even the single pulse is significantly better than the standard spray mode.

 

[Hood]

Here is the whole thread if you fancy a read. Probably not much interest with regards this thread but it did open my eyes as to the low current needed with Mig, I had always thought it would be 200Amps plus for 6mm or so.

Mig vs Tig for aluminium

Someone asked me a question today and I felt I didn't give a satisfactory answer. It was can you mig aluminium, and if you can, why tig? My answer was that tig is cleaner, more precise, produces a better weld with better fusion and the Ac gets through the oxide layer. That sort of thing. So I...

www.mig-welding.co.uk

None of the welds in that thread were done to be pretty as they were all to be a comparison so everything was kept the same, constant motion, no weaving, similar torch ange etc. One thing I really struggled with was welding the small bits with the Mig as normally I am used to doing bigger/longer stuff and I am not used to working at the vice so I wasn't getting comfortable.

 

[Robbie260]

Here is the whole thread if you fancy a read. Probably not much interest with regards this thread but it did open my eyes as to the low current needed with Mig, I had always thought it would be 200Amps plus for 6mm or so.

Mig vs Tig for aluminium

Someone asked me a question today and I felt I didn't give a satisfactory answer. It was can you mig aluminium, and if you can, why tig? My answer was that tig is cleaner, more precise, produces a better weld with better fusion and the Ac gets through the oxide layer. That sort of thing. So I...

www.mig-welding.co.uk

None of the welds in that thread were done to be pretty as they were all to be a comparison so everything was kept the same, constant motion, no weaving, similar torch ange etc. One thing I really struggled with was welding the small bits with the Mig as normally I am used to doing bigger/longer stuff and I am not used to working at the vice so I wasn't getting comfortable.

Have to thank you and all the other participants in that thread and the attached others for thier time and in detail look at the process. That dose put leaning more to the side of having a pulse mig wouldn't exactly be a bad thing. Typically choices seem to get harder not easier.

Dam the limitations of single phase. Though depending on how work decides I'm getting to my next ship in Southampton I may have an opportunity to drop past @Jim Davey and have a chat with them if they aren't busy. Might have the opportunity if the company decides to let me drive as instead of fly to make a small detour via Telford and drop in on @Tom Orrow L.

Probably getting to a point of a choice between:

Bohler
Ewm
Or Lorch

Like the transteel a lot but I don't think I can justify the price also having finally seen the size of one im not sure I have the space for it. Kemppi is still hanging on in the wings as they are nice units.

 

[Hood]

This is 1mm Aluminium that I found lying in the shed, it was corroded and pitted but decided to have a go to see what the EWM would do on 1mm thick so gave it a quick clean.
That was when I was fairly new to pulse Mig so I could do a better job now but even then it impressed me.

 

[finyuk2005]

Its impressive how much the mig punches in there!
What is it about the pulsed mig that looks like it penetrates even more?

 

[Hood]

Its impressive how much the mig punches in there!
What is it about the pulsed mig that looks like it penetrates even more?

I think it just seems to be more focused, tried with force arc on some pieces and it didn't really make much difference, then again I think force Arc is meant more for steel.

 

[andymdavey82]

If @Jim Davey hasn’t already picked up on this thread, then I’ll make sure you have a quote for the EWM tomorrow.

 

[Robbie260]

If @Jim Davey hasn’t already picked up on this thread, then I’ll make sure you have a quote for the EWM tomorrow.

Cheers Andy much appreciated.

 

[andymdavey82]

Cheers Andy much appreciated.

No probs!

 

[Robbie260]

Right well having talked to @Tom Orrow L via email. And @Jim Davey on the phone as well as with @andymdavey82 and Jim via message.

I must thank all 3 of you for your time and brilliant knowledge on the subject.

Though I now have a slight complication as both Tom and Jim have thrown an extra welder each into the ring.

Tom has suggested the Cebora pocket pulse, which I have read @Hoods fantastic review of and it sounds a good machine and may do for my application.

Jim has suggested the Gys neo pulse 220 which I have heard of in passing but don't know much else about other than what Jim has kindly gone over with me, which I must say makes it sound a cracker of a welder. Anyone have any experience with one who could add anything about it.

 

[Jim Davey]

We’ll send you a price for a Pocket Pulse on Monday. That’s not a bad little set to throw into the mix.

 

[Robbie260]

We’ll send you a price for a Pocket Pulse on Monday. That’s not a bad little set to throw into the mix.

Thanks Jim much appreciated.

 

[Dexy]

I bought NeoPulse 220 XL it takes the 15 kg reels no problems got it from Jim at HIS did mention GYS early in this post just thought you didn't like GYS. No issues and the pulse works great you will also get a visit from the GYS Expert to do some demo work if you want and show what it can do lots of menus and tips pointed out by him this was arranged by Jim when i bought the welder note does not come with Aluminium feed rollers