Flux core welding wire

If you're wanting to weld thin metal, say 1/8" or thinner, then mig is the way to go. Otherwise, a good stick machine may be your best bet.

Also, you do have to use sheilding gas when welding aluminum, regardless of the process, i.e. tig or mig.

OK-AL

up to a point you can do anything with wire you can do with stick... if you buy enough amperage.

but on the other end of the scale... with light guage material... wire is the only way to go.. I use wire almost exclusively from 14 guage up to 3/8 material. Gas shielded leaves the weld area virtually clean... flux core is really meant for times when you are working outside and the wind would blow away your shielding gas. BUT flux core is not as clean welding as gas shield... lots of splatter to clean up after.

I agree with the auto dark helmet.. it's made me a much better welder... with wire OR stick. I've got a 100 amp Hobart 'suitcase' 110volt welder for very light guage (.023 wire), a Millermatic 200 for heavier stuff (.035-.045 wire) and an old Lincoln 225 ac/dc tombstone for stick... but it hasn't even been plugged in in years. a little practice with wire will make a believer of you.. much easier to start without sticking (for me anyway) and produces just as stong welds.

We welded a double set of discs that had the back section torched off... it was 2x4 rectangular tubing... we just cleaned up the area to be welded with a grinder and clamped it back together. one pass around than added 3/16" thick 4" bar stock patch plates on inside and outside with full weld around it... drug it around all day and it's still holding... one more thing.... wire welding wants a much cleaner weld area than stick... it's much less forgiving on weld prep.

later
john