What is the suggested current range for 1/8 inch aluminum when using spray?

The suggested current range for welding 1/8 inch aluminum using the spray transfer method is indeed around 110-130 amps. This range is optimal because it provides sufficient heat to create the necessary fusion between the aluminum base metal and the filler material while preventing excessive heat that could lead to warping, burn-through, or other defects.

Spray transfer is known for producing a stable arc and high weld quality, which is particularly important in aluminum welding due to its thermal conductivity and the need for a clean, consistent weld bead. In the 110-130 amp range, the welder can achieve a smooth, robust welding arc that enhances penetration and improves the overall appearance of the weld, making it ideal for applications where structural integrity and aesthetic quality are paramount.

Using a current lower than this suggested range may result in inadequate penetration and poor weld strength, while a higher amperage could overheat the material, leading to undesirable outcomes such as excessive distortion or compromised mechanical properties of the aluminum.