Welding aluminium.

[Rob Dome]

In my experiance the Lincoln Power MIG 350MP with the aluminum push-pull gun is the way to go, it's expensive but depending on the size boat is really only a drop in the bucket and can usually be resold after the project is done. On that note I would recomend that you stick with a name brand welder. Also aluminum particulates have been sujested to be a factor in Alzheimers, so WEAR A REPIRATOR AT ALL TIMES.

Also the learing curve for any wirefeed process is considerably less than stick or TIG.

http://www.mylincolnelectric.com/Cat...et.asp?p=18686

[Pavel]

I have one thing to add to the above, absolutely go for the best (and possibly the most expensive) welding machine after you try several. It will pay off. We have bought ESAB aristo 400 with their push-pull system and its NOT an aluminium welding machine despite what they would claim. Check the Fronius aluedition 240, we have seen it and test it. Its a paradise to weld with it. At a cost (we dont have it (yet)).
Also dont get fooled when trying the machine, they would usually test it for you with AlSi wire, insist on AsMg which you are going to use. Its much easier and nicer to weld with AlSi wire, but its useless for marine use. Enjoy.

[Pavel]

sorry, one more thing to add to toxicity of aluminium fumes. There were several reports and studies without any evidence that aluminium welding fumes actually caused any problem on prof-alu-welders (in contrary to stainless steel welders for instance). You can check google for yourself. However, there were several studies showing no evidence for lung cancer caused by smoking ... the choice is yours, as much is your health. Personally I find respirator very annoying to work with, and impossible while you wear helmet. Anyway...

Pavel, do you really believe that ANY welding smoke is good for you? Everyone else, wear your respirator now, so you don't need one later with oxygen. Ask firefighters about any smoke being SAFE.

[Pavel]

I dont think anyone can actually weld with a respirator and welding helmet on, at least not on a long term. Check the helmets which have the possibility to blow air through it, it might be a solution for some of us healthy conscious (me inclusive, otherwise I would not read through the numerous alu-welding/health reports). However, as with anything else, its a question of sustainable risk. If prof-alu-welders being exposed for eight hours per day for many years to alu-fumes and arguably show no or little sign of any health trouble, you as well might take it easy if you are building one off boat. Aluminium penetrates via skin by mere touching it... this cause a multiple sclerosis and potentially other nasty sicknesses. Should we forget about aluminium all together?

I weld occasionaly. I now set a 2' floor fan blowing at me. Not enough to change the weld quality. But enough to carry the fumes away from my mouth. If you do not help ypurself, no one else will. No employer or OSHA cares how you do it. Take the time to buy a couple of fans and extension cords to work in the different spaces you weld in. Take care of yourself, Rich. If you weld in large structures, use a fan, chain and a C clamp to hold it right.