Stick Welding Aluminum with an Everlast DC inverter PowerArc 300

This video demonstrates the little known welding capability of a DC stick welder to weld aluminum.

[KnolltopFarms]

Boy, you sure gotta get up and run along fast with those rods! Thanks for the video...and thanks for the Everlast 160sth, it's 4 years old and is still running strong. I love my little green monster!

Aloha, the Farmer.

[everlastgenerator]

That's a frequent question we get, and probably one we should do a video on. Aluminum was originally welded with a DC welder, but it was not a good solution. It required a very large tungsten for even relatively low amperages because it concentrated too much heat on the tungsten in DC+ (used because it offered cleaning action) and offered low penetration. DC- was used as well for a time, but it was difficult. In short, the PA 140ST could be used, but won't be good solution.

[nicksluder]

That looks a lot better than I expected it to. 👌 Thanks for the info!

[everlastgenerator]

It's not required. But I imagine preheating would extend the capacity of the welding rod. If it's too hot, the weld goes runny. The flux just melts off like hot ice cream.

[lewisdrake]

Cool video. I might give aluminum stick welding a try with my everlast welder.

[everlastgenerator]

It's best to let the metal cool somewhat between passes.

[martinjoseph]

Pretty neat. I found out about stainless steel stick electrodes recently too. I will need to give both a try on my PowerArc welder. Thanks for the video and the review.

[scootergeorge]

When I did Tig aluminum welding for Trek bicycle we always used AC current and argon gas. Strange AC does not work for stick. With tig, as the base metal heated we would decrease current with a foot pedal. Here, the only option seems to be speed. Correct?

[TheTitaniumSkull]

I have been stick welding aluminum since 1995 and can say that it is still a bear to deal with, Glad my Everlast 205 SI is on order and due to be shipped in a few weeks. Its like Christmas for me.

[garymathews]

angle the welding rod to put a little more of the bead on the vertical side of the weld .save any alum rod as a filler for big gaps use .

[martinjoseph]

that is a pretty runny flux once the metal heats up. very interesting video. I can't wait to see what your new PowerArc welders are like.

[everlastgenerator]

Keep a tight arc with the front edge of the electrode dragging on the metal at all times if possible for best results for stainless and also for aluminum, though the aluminum burns so fast, it is hard to do. At least in stainless, if you have too long of an arc length, you will get porosity below the surface, even though the top looks perfect.

[jskdrummer]

I got some 3/32 blue demon rods and couldnt get them to run for crap. Regardless what amperage I used the rod would just melt away and not deposit hardly any material. When I could get it to run for a few seconds Id get piss poor fusion of the joint rather it would just make a tall glob of a bead. Im not perfect but I can run pretty dang good with common mild steel electrodes and even stainless steel electrodes so I don't think user error was the case here. Not sure if it was the brand of rods I used but it's a shame I was really hoping this would be an option for field work. Gona have to stick with tig/mig.

[philquinn]

The "s" in smaw stands for shielded

[tank]

thanks I wanted to know because I have a friend who asked me to weld some cosmetic panels on the side of his aluminum dune buggy and I currently only own the 140st because my big nicer welder blew up on me and the warranty just ran out 2 weeks earlier.

[taz]

Dang man those things go quick. Pretty interesting

[everlastgenerator]

This video was not as a result from a directive from the home office. It was in response to several questions individuals had directed my way and asked us to address. It had been in planning stages for several months.

[Sky-epdw]

It will be helpful if you shows the cross section of the weld. but this is very helpful video, thank you!

[kargmeister]

My buddy asked me to weld up his aluminum frame for a dirt bike with a stick welder.  I've used tig and wire feed for aluminum but never a stick welder.  I just can't remember if the hobart welder he had was only ac or if it was dc as well. 

[kenmcf]

I want to build a sliding gate from with metal tubing(1 1/2 x .75) around 16 guage. I saw some aluminum tubing same size at 1/8 inch thickness. so for the amount of welding there, just joining up the tubes at the intersections, could I stick weld it....I am in the process of learning. I just took a class on MIG but if i buy a welder a stick looks way more versatile and cost efficient.