february2023 - 18

COVER STORY
ALUMINUM REPAIR
One of the advantages to using a MIG
machine or process is that you can weld
steel and aluminum without much
difficulty or training (especially with
newer machines that are more automated
for the correct amperages and
wire feed speeds. More on that later).
" Normally, when you [weld
MIG welders are the most commonly used welding machines in body shops with the ability to plug
weld panels of various thicknesses and materials. Today's machines are also more automated so
they are easier to operate. (Image: Forney's new 190 multi-purpose MIG/TIG/Arc machine.)
MIG machine, mainly because the
technology made them more difficult
for the beginning welder. And they
were much more expensive and heavier.
But today that's changing with new technology,
which is allowing for easier manufacturing
processes and more affordable
options along with lighter weight.
" Twenty years ago, almost everyone
used the dedicated MIG machine, and
they were based on a transformer-style
power supply. It was expensive and
challenging to make a multi-process
machine. But now that most welding
machines are based on PCBs (printed
circuit boards), it's much easier to make
a multi-process machine with modern
technology. It used to be that if you
wanted to change from MIG welding
to stick welding or TIG welding, it was
challenging. It might take a technician
five or 10 minutes to change over.
It takes about 30 seconds to change
from MIG welding to TIG welding.
Technology has changed a lot in recent
years. And so I would say nowadays,
there are not a lot of downsides. We
intentionally design our machines for
quick changeover between processes
and very simple controls, just for that
reason, so it's easy to change. "
With the changing technology
comes lighter weight and more options
from a manufacturing standpoint, so
many body shops are now opting for
the MP machines. Mahugh points out
that while most techs use MIG for collision
work, some of these body shops
also work on weekend projects, such
as a motorcycle or go-kart on the side.
" The shop owner or tech may want to
use TIG for the Chromoly tubing on
his go-kart or something like that, or
maybe even has a race car with a cage
that needs to be welded. So that's where
the value of the multi-process machine
can come into play. "
A MP machine can also stick-weld,
but that's not a process used very often
in automotive shops anymore unless
it's for frame work or some sort of
trailer accessory with very thick metal.
Still, it's a good option to have when
the need arises.
18 Professional Distributor I February 2023 I VehicleServicePros.com
aluminum] you use a spool gun that
attaches to your MIG machine, " says
Mahugh. " And that allows you to
feed the soft aluminum wire a short
distance, which is a problem with
MIG welding aluminum. The wire is
so soft it's hard to feed 15 feet. So a
spool gun with a small one or twopound
spool of wire on the gun only
pushes the wire maybe eight to 12
inches. It's much easier to push a rope
8 to 12 " than it is to push a rope 10 or
15'. That's the concept with aluminum
spool welding. "
More independent body shops are
welding and repairing aluminum than
ever today, so Mahugh says it can be a
benefit to have a MIG machine that is
set up to do both steel and aluminum
with little fuss.
" One of our machines (the 242 Dual
MIG) is set up where you can run steel
out of the machine, but then you can also
have an aluminum spool gun hooked up,
and all you have to do is flip a switch. So,
one minute you're welding steel, and the
next minute, you're welding aluminum
with just the flip of a switch. There are
things like that we try to accommodate
because a lot of body shops are doing
aluminum repair now. I almost never saw
a body shop do aluminum 10 years ago.
Now, quite a few body shops are doing
aluminum, particularly with the Ford
F-150, and some of the European cars
use a fair bit of aluminum as well. "
Some body shops may even want
to set up a separate MIG welding
station for aluminum just to keep
them apart because some of the
hammers and tools also need to be
Photography: Forney Industries

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february2023

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