For 1/8 inch aluminum, what is the wire feed speed using .035 spray?

The appropriate wire feed speed for welding 1/8 inch aluminum with a .035 wire in spray transfer mode falls within the range of 350-400 inches per minute. This range is crucial for achieving proper penetration and a stable arc, which are essential when working with aluminum due to its unique properties, such as high thermal conductivity and low melt point.

Spray transfer mode requires a higher heat input, which is facilitated by the faster wire feed speeds that help maintain a sufficient arc length and allow for a smooth weld bead. When using a .035 diameter wire, the chosen speed ensures that enough filler metal is being deposited while preventing issues such as burn-through or lack of fusion.

The other ranges reflect speeds that either exceed the operational parameters effective for .035 wire or do not provide sufficient energy transfer to ensure a quality weld on 1/8 inch aluminum. Understanding the interplay between wire diameter, material thickness, and feed speed is essential for successful MIG welding applications.