Miller's AlumaFeed Synergic Aluminum Welding System is designed for MIG and pulsed MIG aluminum applications

Miller Electric Mfg. Co. has introduced its AlumaFeed Synergic Aluminum Welding System for high-volume, high arc-on time industrial aluminum applications requiring conventional MIG and pulsed MIG welding outputs. Designed for simplicity, experienced MIG welders require no learning curve to understand system controls, and novice welders can make production-quality pulsed MIG welds within hours using the system’s synergic control and the Profile Pulse output.

The AlumaFeed System consists of the AlumaPower 350 MPa synergic power supply (an 80-pound inverter with an output of 5 to 425 amps/10 to 38 volts and built-in programs for 4000 and 5000 Series aluminum); the lightweight XR AlumaFeed wire feeder/control module (42.5 pounds) and the XR-Aluma-Pro or XR-Pistol Grip gun (air- and water-cooled models available in 25- or 30-foot length options).

With optional extension cords, an operator can take the wire feeder up to 100 feet away from the power source, providing an extended reach that improves production efficiency when welding inside hulls or tanks, or maneuvering around large weldments.

The AlumaFeed System simplifies and improves aluminum welding through a combination of features:

  • “One-knob” synergic control using the wire feed speed control on the gun. After system set-up (selecting wire diameter, type of welding output), operators simply increase wire feed speed to weld faster/increase penetration/deposition and decrease wire feed speed to weld slower/decrease penetration/deposition. Synergic control eliminates the need to adjust multiple parameters to fine-tune the arc when MIG and pulsed MIG welding, reducing training time.
  • The Profile Pulse pulsed MIG output creates a “stacked dime” or TIG-like bead profile without torch manipulation, making it easier for less-skilled operators to create weld beads with high aesthetic appeal.
  • Hot Start function reduces incomplete fusion or cold lap at the beginning of a weld (a common issue with aluminum). A crater function gradually decreases weld current at the end of a weld to help eliminate defects that lead to crater cracking. 
  • True push-pull wire feed technology. A high-precision torque/slave motor inside the wire feeder and pull motor inside the gun work together to maintain consistent wire tension, even when the gun cable may be angled around weldments. Consistent proper wire tension ensures smoother wire feeding and steady arc performance, and it reduces the bird’s nesting and burn-backs normally associate with aluminum feeding. 
  • The system includes a parameter range and a system lock function that can be used to ensure that all operators and all shifts weld according to specified procedures, helping to ensure consistency and quality.
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