ER4047 Aluminum Mig Welding Wire

How to optimize MIG welding parameters for ER4047 wire? A guide to current, gas and speed

ER4047 (aluminum-silicon alloy, containing 12% silicon) is widely used in thin plate welding, automotive parts and refrigeration industries due to its excellent fluidity, crack resistance and heat resistance. However, aluminum welding is parameter-sensitive and requires balancing key factors such as current, gas and wire feed speed. The following is a practical guide to optimizing MIG welding parameters:

1. Shielding gas selection

Recommended gas: pure argon (Argon 100%).
Argon can stabilize the arc and reduce oxidation, making it suitable for aluminum welding;
Avoid using mixed gases containing helium (He) (such as Ar/He) unless higher penetration is required (but ER4047 is mostly used for thin plates and usually does not require additional penetration).
Gas flow: 15–25 CFH (7–12 L/min), ensuring coverage of the welding area and avoiding pores.

2. Current and voltage settings

Polarity: DC reverse connection (DCEP), ensuring cathode cleaning and breaking the oxide film on the aluminum surface.
Parameter reference (according to plate thickness):

Thin plate skills: reduce current (avoid burn-through) and increase welding speed;
Thick plate skills: appropriate preheating (100–150°C) to reduce thermal stress.

3. Wire feeding speed and welding gun angle

Wire feeding speed: needs to match the current. Too fast will easily cause spatter, and too slow will cause poor fusion;
Recommended starting value: 6 m/min, fine-tuned according to weld formation.
Welding gun angle: push welding method (10°–15° tilt) to improve gas shielding effect.

4. Welding speed and heat input control

Thin plate (<3mm): high-speed welding (30–50 cm/min) to reduce heat accumulation;
Thick plate: appropriately reduce speed (20–30 cm/min) to ensure penetration.
Key point: maintain uniform speed and avoid pauses (aluminum conducts heat quickly and is prone to forming concave or nodular welds).

5. Common problems and solutions

Porosity: Check gas purity (≥99.99%), clean the base material (remove oil/oxide film);
Unfused: Increase current or reduce welding speed;
Cracks: Control interlayer temperature (≤150°C) to avoid silicon segregation.