MIG Welding

We recently had a project using 16 gauge aluminized steel and found it was better to grind off the aluminizing and drop our wire size to .025 in. The thickness of the metal you are welding is pretty thin. Can you back the material with copper prior to welding? Wire fed TIG might be a solution

TRY TIG AC Autogenous - means no rod filler .

Let steel melt-and join itself and Al coating to melt and join Al toAl .

You may finally have to do in 2 passes:

#1 MIG WITH MS WIRE 0.6MM auto feed.

#2 TIG AC with Al wire 0.6mm hand feed.

We regularly TIG weld steel from 1mm down to 0.1mm, mostly around 0.5-0.7mm & have to get vacuum tight joints. The joints are normally circular & welded using a motor driven turntable and fixed torch. We don't use any filler, just use as light a weld as possible but any gap in the joint will cause it to blow through.

Has anyone tried pulsed mig, I know pulsed tig would be easy for this but for a semi-auto mode?

I understand it is difficult to weld a thin material. For a 0.8mm steel i suggest to use welding current (wire speed) around 63 ipm. Then adjust your voltage to get the desire 'weld bead'. You must use 0.8mm wire diameter to weld thin material.

You may also try to use Accu Pulse Welding Method if it is supported by your Welding set. Please contact your welding set supplier to get help on proper welding parameter if using accu pulse.

Copper Backing Bar or Plate which is place at the back of the welding point will help to absorb heat and thus solve welding hole issue. But copper backing bar/plate usage is limited to part and/or jig design.

Hope this would solve your problem.