0.035 is gonna be next to impossible to push through a standard mig cable even with teflon and U rollers.

0.045--3/64 stands a better chance to be pushed through your teflon liner...

If you can change to 5356 filler try that.. it is stiffer

Keep your cables as straight as possible

Pressure on your rollers should be lighter than with steel

TJ,

While I haven't had any experience with a LN-25 on aluminum, I was once required to use a little miller fluxcore hobby machine to do aluminum welds, and here is what I was told would help:

1) Use 5356, as it is stiffer and will be less likely to collapse as it is being pushed

2) Use a size larger tip to keep the aluminium from expanding and galling up inside of the tip

3) The shorter the gun line, the better. That teflon liner will help a little, but 12 foot is a long way to push aluminum.

We did not change drive rolls, and that may help keep from deforming the al. All that said, I had very little luck obtaining quality welds (the welds I was able to get down were in between many, many birdnests). Fortunately, they were not critical and all that was necessary was a "glue" to keep vibrations to a minimum. When I have used the LN, it was, however, a far superior machine, and I would not doubt that you will have better luck than I did once you figure out parameters.

HTH,
G. L.

Hi TJ,

First, do not try anything to “clean/lub” Al wire. It will contaminate the wire. Second, you have to change the drive rolls to U groove, V groove is for solid steel wire only. Aluminum is softer than steel, V groove will damage aluminum wire surface causes bird nest or other quality problem.
Recommendation for Aluminum welding set up: a). U drive rolls (KP654-035A Drive Roll Kit - .035" (0.9mm) Aluminum Wire, much cheaper than clutched ones), b). Teflon liner, c) contact tip (I don’t remember the part number, the diameter is bigger than that for steel, but you can use 045’’ normal tip for 035’’ aluminum wire, it works).
Try WFS 500-550 ipm, 21-22V, half inch stick out, lead angle (left hand direction).
By the way, what’s the 4035? I don’t know this wire, I know 4043 and 4047.
You will get there for sure.

Good luck!

Gong