Spool guns

Introduction

In the world of welding, the right tools can make all the difference. Among these, spool guns have emerged as a vital asset, particularly for welding aluminum. This comprehensive buyer's guide will delve into the power of spool guns, their benefits, key features to consider when buying, and top brands and models available in the market. We will also unlock the secrets to maximizing the power of your spool gun through proper setup, usage, maintenance, and advanced techniques.

Understanding Spool Guns

A spool gun is a pistol grip style welding tool with a compartment for a wire spool roll to be attached directly onto the gun. It has its own drive rollers inside, allowing the wire to feed from the spool, through the gun, and out into the weld. The wire only has to travel the length of the gun, reducing potential issues. Spool guns are particularly effective for welding aluminium, preventing common problems like birdnesting and wire kinking. However, they are best suited for smaller applications or occasional use due to their lower duty cycles and inability to weld very thick material.

The Basics of Spool Guns

Spool guns are a crucial addition to Mig welders, especially for welding aluminum. They function by feeding the wire from the gun itself, which is beneficial when using softer wires like aluminum. The spool gun motor and the feed motor should be of the same voltage for optimal performance. Two aluminum welding processes are introduced when a spool gun is added: short circuit transfer and spray transfer. Short circuit transfer involves a controlled short circuit where the wire melts as it's fed into the grounded object. Spray transfer, on the other hand, occurs when the wire melts mid-air, and the current flow pulls it into the puddle.

Benefits of Using Spool Guns

Spool guns offer several benefits when it comes to welding, especially with aluminium. They eliminate common issues like birdnesting and wire kinking, saving time and material. Spool guns are ideal for smaller applications or occasional aluminium welding due to their lower duty cycles. However, they may be bulkier and heavier than other guns, which can make it harder to access tight spots. Despite these challenges, spool guns are generally more affordable than their counterparts, such as Push-Pull guns.

Key Features to Consider When Buying a Spool Gun

When buying a spool gun welder, consider its length, wire size, spool size, and feed rate. The length should be sufficient to reach all corners of your workpiece, with 10 feet being ideal for small projects and up to 20 feet for heavy-duty usage. The wire size your spool gun can handle is also crucial, with most models accommodating up to a 0.035-inch thick wire. The spool size, usually given in diameter, determines how much wire you can store; a 4-inch spool is common. Lastly, consider the feed rate, which affects the speed of your welding process.

Power and Performance

The Magnum® SG spool gun stands out in terms of power and performance. It's a semi-automatic spool gun designed for reliable aluminum wire feeding with various CV power sources and engine-driven welders. With a rating of 250 amps at 60%, it ensures efficient performance for your welding tasks. The gun features a generous 25 ft (7.5 m) gun cable and integrated wire feed speed control in the handle, reducing the need for frequent trips back to the power source. This spool gun is not only powerful but also easy to set up and operate, making it a valuable addition to your welding tool set.

Durability and Build Quality

When it comes to durability and build quality, the Lotos Technology MSG094 spool gun welder stands out. It's the most durable and reliable option, offering an excellent build quality. The brand also provides a 1-year long warranty, which is much higher than other options. On the other hand, the Hobart 300796 spool gun welder, despite having a warranty of just 3 months, offers a decent build quality. However, the build quality of the Lincoln Electric spool gun welder is quite average.

Ease of Use and Maintenance

The Longevity MIGWELD 140 welder and SPOOLGUN 140 combo is designed for ease of use and maintenance. The welder easily connects to a standard 110v wall outlet and can be set up in minutes. It's equipped with Tweco-style connectors, allowing easy swapping of torches. The MIGWELD 140 panel allows quick and accurate viewing of settings, and with variable adjustment dials, users can fine-tune the welder for precise welding. The welder also comes with a mild steel 1lb welding wire roll, welding mask, chipping hammer, welding brush, and gas regulator, providing an all-in-one package for immediate use.

Price and Warranty

The Longevity SPOOLGUN 140 MIG Gun comes with a six-month warranty on parts and labor, providing buyers with a safety net should any issues arise. It's important to note that the wire spool is not included with the purchase. For detailed warranty information, it's recommended to check Longevity's terms and conditions. The price of the product is not mentioned in the original content, so potential buyers are advised to check the Alibaba website or contact the seller directly for pricing details.

Top Spool Gun Brands and Models

One of the top-rated spool guns on Alibaba is the AMICO POWER 15 ft. 250 Amp SPG15250. This professional-grade spool gun is designed for welding aluminum and is compatible with AMICO MIG-140GS/160GS/200GS and MIG-160/180/200 models. Its robust build and high power output make it a reliable choice for both professionals and hobbyists. The 15-foot length provides ample reach for various welding tasks, and the 250 Amp rating ensures powerful performance.

Brand 1

The Spoolmate™ 150 Spool Gun is a notable product in the spool gun category. It's recommended for feeding flux cored wires and is compatible with Spoolmate 100, 185, and 200 MIG guns. The Spoolmate series spool guns utilize contact tips, sold in packages of five, and are compatible with the Spoolmate 3545-20 and Spoolmate 200. This product is designed to enhance efficiency, save money, and optimize operations through advanced welding processes. It's user-friendly, offering auto-settings and improved visibility for a better user experience.

Brand 2

Brand 2, known as the 'Brand mono block directional control valve', is a versatile spool gun available in one (TS1), two (TS2), and three (TS3) spool configurations. This spool gun is designed for applications where separate circuits need to be operated independently. It offers parallel, tandem center 4-way, open center 4-way (motor spool), and tandem 3-way spools. An added advantage is that the valve is field convertible to closed center or power beyond, providing flexibility in various operational conditions.

Brand 3

Lotos Technology’s MSG094 spool gun welder is a highly reliable and durable option. It offers an excellent build quality and a 1-year long warranty, which is much higher than other options. The length of this spool gun welder is 9 feet, and it supports the standard wire size of 0.035 inches. It offers a high wire feed speed of up to 13 m/min, making it a great choice for various welding tasks.

Unlocking the Power of Your Spool Gun

To unlock the power of your spool gun, preventive maintenance is crucial. Start with a thorough inspection of the gun and work your way back to the wire feeder. Ensure all connections are secure to prevent poor electrical conductivity, which could lead to weld defects and overheating. Pay attention to the gun liner, a common source of poor wire feeding and unscheduled downtime. Follow the manufacturer’s instructions for proper trimming and installation. Front-end gun consumables such as gas diffusers, nozzles, and contact tips are constantly exposed to heat and spatter, so preventive maintenance can extend their life and improve gun performance.

Proper Setup and Usage

Adding a spool gun to a Mig welder for welding aluminum involves several steps. First, remove the welder's outer cover and inspect the motor's voltage. Next, wire up the switch and the welding lead. Install the switch, replace the cover, and you're ready for welding tests. Two aluminum welding processes are introduced by adding a spool gun: short circuit transfer and spray transfer. Remember, using 100% argon for these welds is crucial as a normal bottle of mig shielding gas for steel won't work. This modification can significantly enhance your welding setup.

Maintenance and Care Tips

Maintaining your spool gun is crucial for its longevity and performance. Regularly check the contact tip, as it's the most worn item. Signs of wear include an oval-shaped orifice and discoloration. Ensure the contact tip is tightly threaded to avoid high resistance and premature wear. Avoid using oversized contact tips and changing them prematurely. Also, be cautious with anti-spatters and chemicals as they can cause residue build-up. Lastly, don't file contact tips as it can make the inner bore uneven. Following these tips will help you get the most out of your spool gun.

Advanced Techniques and Tips

When welding aluminum with a spool gun, use a short-circuit arc, which produces a 'frying bacon' sound. This requires a quick movement of the gun. Always use a push technique with a 20-degree work angle for proper gas coverage. Experiment with gas flow, starting at 35 CFH. Ensure sufficient wire 'stick-out' of 3/4 inch. Minor adjustments to wire feed speed and voltage can help achieve ideal penetration and bead contour. Cleanliness is crucial, so use a degreaser and a stainless steel wire brush before welding.

Conclusion

Spool guns have revolutionized the welding industry, particularly in the realm of aluminum welding. Their unique design and functionality eliminate common issues like birdnesting and wire kinking, making them an ideal choice for smaller applications. When purchasing a spool gun, it's crucial to consider factors like length, wire size, spool size, and feed rate. Brands like Magnum®, Lotos Technology, and Longevity offer some of the best models in the market. To unlock the full potential of your spool gun, preventive maintenance, proper setup, and usage are key. By following the tips and techniques outlined in this guide, you can ensure optimal performance and longevity of your spool gun, thereby enhancing your welding setup.