Best Spool Gun for Aluminum Welding

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Are you in the market for the best spool gun  for aluminum welding and do not know what machine to settle for and the things to look out for?  You need not worry anymore as you have landed on the best site.  In this review guide, we have looked at the 7 best spool guns you can always use for your aluminum welding together with a number of factors you need to consider when shopping for one.

So, what is the best spool gun for aluminum welding? We did find the Hobart Spool Gun, 150 A, 10 ft, 60 percent as the overall best. This spool gun is well equipped as it comes with a wire feed and a wire speed feed control.  Using it is not that difficult and high quality materials have been used in making it. It has extensive safety features together with different voltage settings.

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The Test Winner After 21 Hours Of Research:

HOW WE DECIDED

--We researched every product, we review with our own.

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17

Researched Source

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21

Hours Researched

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10

Experts Interviewed

4

218

Consumers Review

Product Image
Top Pick
Spool Gun, 150 A, 10 ft, 60 percent
Lincoln Electric Magnum PRO 100SG Spool Gun - for Aluminum MIG Welding - Compatible...
Lotos Technology MSG094 Spool Gun for Aluminum Welding for Lotos MIG Welders MIG140,...
LOTOS MIG175 175AMP Mig Welder with Free Spool Gun, Mask, Aluminum Welding Wires,...
Hobart 300349 DP-3545-20 Spool Gun
Klutch 150 Spool Gun Kit - fits Klutch MIG250S, MIG140Si and MIG/Stick 220Si Welders
Voltage
115 V
120 V
120 V
220 V
115 V
115 V
Style Spool Gun
Spool gun
Spool Gun
OH style
Spool Gun
Screw-style
Tweco-style
Installation Method [Mig-welding]
Mig Welding
Mig Welding
Mig Welding
Mig Welding
Mig Welding
Mig Welding
Cable Length
10 ft
10 ft
9 ft
6ft
20 ft
10 ft
UNSPSC Code
23270000
27000000
27000000
23271700
23270000
23270000
Field of Application [Aluminum/steel]
Aluminum
Aluminum
Aluminum
Aluminum
Aluminum
Aluminum
Includes Component
Spool Gun , gas hose and 10 ft Cable
Spool Gun & 10 ft Cable
Spool Gun &9 ft Cable​
Spool Gun, Standard MIG Gun
Spool Gun, 20 ft cable & Argon Regulator
10 ft cable, spoon gun
Prime Status
-
-
-
Top Pick
Product Image
Spool Gun, 150 A, 10 ft, 60 percent
Voltage
115 V
Style Spool Gun
Spool gun
Installation Method [Mig-welding]
Mig Welding
Cable Length
10 ft
UNSPSC Code
23270000
Field of Application [Aluminum/steel]
Aluminum
Includes Component
Spool Gun , gas hose and 10 ft Cable
Prime Status
-
Available
Product Image
Lincoln Electric Magnum PRO 100SG Spool Gun - for Aluminum MIG Welding - Compatible...
Voltage
120 V
Style Spool Gun
Spool Gun
Installation Method [Mig-welding]
Mig Welding
Cable Length
10 ft
UNSPSC Code
27000000
Field of Application [Aluminum/steel]
Aluminum
Includes Component
Spool Gun & 10 ft Cable
Prime Status
Available
Product Image
Lotos Technology MSG094 Spool Gun for Aluminum Welding for Lotos MIG Welders MIG140,...
Voltage
120 V
Style Spool Gun
OH style
Installation Method [Mig-welding]
Mig Welding
Cable Length
9 ft
UNSPSC Code
27000000
Field of Application [Aluminum/steel]
Aluminum
Includes Component
Spool Gun &9 ft Cable​
Prime Status
Available
Product Image
LOTOS MIG175 175AMP Mig Welder with Free Spool Gun, Mask, Aluminum Welding Wires,...
Voltage
220 V
Style Spool Gun
Spool Gun
Installation Method [Mig-welding]
Mig Welding
Cable Length
6ft
UNSPSC Code
23271700
Field of Application [Aluminum/steel]
Aluminum
Includes Component
Spool Gun, Standard MIG Gun
Prime Status
Available
Product Image
Hobart 300349 DP-3545-20 Spool Gun
Voltage
115 V
Style Spool Gun
Screw-style
Installation Method [Mig-welding]
Mig Welding
Cable Length
20 ft
UNSPSC Code
23270000
Field of Application [Aluminum/steel]
Aluminum
Includes Component
Spool Gun, 20 ft cable & Argon Regulator
Prime Status
-
Available
Product Image
Klutch 150 Spool Gun Kit - fits Klutch MIG250S, MIG140Si and MIG/Stick 220Si Welders
Voltage
115 V
Style Spool Gun
Tweco-style
Installation Method [Mig-welding]
Mig Welding
Cable Length
10 ft
UNSPSC Code
23270000
Field of Application [Aluminum/steel]
Aluminum
Includes Component
10 ft cable, spoon gun
Prime Status
-
Available

What Are The Best Spool Gun For Aluminum Welding?

Here are some of the best spool gun for aluminum welding we found:

1. Hobart Spool Gun, 150 A, 10 ft, 60 percent

Salient Feature

  • Voltage: 115 V
  • Style Spool Gun: Spool gun
  • Installation Method: MIG Welding
  • Cable Length: 10 ft
  • UNSPSC Code: 23270000
  • Field of Application: Aluminum
  • Includes Component : Spool Gun , gas hose and 10 ft Cable

The Hobart Spool Gun, 150 A, 10 ft, 60 percent is a perfect spoon gun for beginners and professionals. You can start using it immediately you unpack it. Using it is very simple and it does come with everything you might require from a top spoon gun. Its greatest benefits are simplicity, power and versatility.

Features

This Hobart 300796 Spool Runner 100 Spool Gun comes well equipped with a wire feeder and a wire speed feed control. It offers adjustable tension and does offer an adjustable tension while adding a quick release tension lever in its drive system.

The ease of use and adaptability of this spoon gun allows it to be used by people who don’t have enough experience.  It comes with safety features together with readability. Never forget it’s different voltage settings.

Other Features

This spoon gun is compatible with both the 120V and the 220V outlets hat make it easier to use. It is also possible for one to change the voltage of operating it by simply changing the electric cable plug. All you have to do is swap MVP plug from the 120 V to 220 V input power and you will be good to go. It has a 30% duty cycle at 150 amps which is quite low when compared to the other spoon guns in the market.

Pros

  • It is very easy to use
  • Made using sturdy and durable materials
  • Comes with a detailed user manual
  • Has extensive safety features

Cons

  • Quite expensive
  • Most of its cables are a bit short

2. Lincoln Electric K3269-1Magnum PRO 100SG Spool Gun

Salient Feature

  • Voltage: 120 V
  • Style Spool Gun: Spool Gun
  • Installation Method: MIG Welding
  • Cable Length: 10 ft
  • UNSPSC Code: 27000000
  • Field of Application: Aluminum
  • Includes Component : Spool Gun & 10 ft Cable

This Lincoln Electric K3269-1Magnum PRO 100SG Spool Gun is considered to be a perfect machine for newbie. It is very versatile and using it is quite simple. Although it comes with a manual, it is not of great help since it is very simple to set up and start using.

Features

It comprises of four different welders which have all been amalgamated into a single unit and does come with functions of a Stick, MIG, TIG and Flux core spoon gun. It is well designed with quality materials while the layout functions very well which makes it very easy to get used to.

It does have a screen display that contains instructions which allow you to key in variable which you can thereafter set the voltage, fire speed and amperage.  It is a spoon gun capable of working on any metal but does not have an AC output option.

Other Features

It performs very well when compared to the other spoon guns reviewed in this guide. For sure, it can easily surpass the three year warranty period it comes with due to its high quality materials used in making it.

Pros

  • Perfect machine for a starter
  • Made using top quality materials
  • Can work on any type of metal
  • Very easy to set up

Cons

  • Does not have an AC output for the TIG aluminum
  • Needs lots of maintenance to remain in good condition

3. Lotos Technology MSG094 Spool Gun

Salient Feature

  • Voltage: 120 V
  • Style Spool Gun: OH style
  • Installation Method: MIG Welding
  • Cable Length: 9 ft
  • UNSPSC Code: 27000000
  • Field of Application: Aluminum
  • Includes Component : Spool Gun &9 ft Cable

The Lotos Technology MSG094 Spool Gun is considered to be a value choice by most people. In case you are in need of a spoon gun that will assure you great returns, then the Lotos Technology MSG094 Spool Gun is the perfect choice for you.

Features

This spoon gun comes with an aluminum wire feed drive and can easily mount on both the 4 inch and the 8 inch spools. It comes with two snazzy digital displays; one shows the wire speed while the other shows the arc volts. Both are in a separate visual display which makes the unit easy to understand and control.

This spoon gun also comes with a 2T/4T switch that you can always use the switch instead of trigger on the gun. This makes it possible for you to turn the power on without having to press the trigger.

Other Features

This spoon gun has a very reasonable duty cycle 20% at 90 amps.  It also comes with a thermal overload protection that helps in protecting the spoon gun from overheating especially when the user goes past its duty cycle. You can automatically turn off the torch to help protect the user.

Pros

  • Comes ready to use
  • Has a variable wire feed speed dial
  • Has an average duty cycle of 30% at 90 amps
  • Has a very solid aluminum wire feed drive

Cons

  • Frequent wire feed problems
  • Not that durable like the other spoon guns

4. LOTOS MIG175 175AMP MIG Welder with Free Spool Gun

Salient Feature

  • Voltage: 220 V
  • Style Spool Gun: Spool Gun
  • Installation Method: MIG Welding
  • Cable Length: 6ft
  • UNSPSC Code: 23271700
  • Field of Application: Aluminum
  • Includes Component : Spool Gun, Standard MIG Gun

In case you will not mind going for a low quality welder but in need of more diversity in your welding, then the LOTOS MIG175 175AMP MIG Welder with Free Spool Gun the best choice for you.

Features

This LOTOS MIG175 175AMP MIG Welder comes with an argon shielding together with a roll feed wire which couples 175 watts of arc. It is well designed to use the flux core and uses its own gas regulator. This makes it possible to weld anything right from stainless steel, aluminum and steel. It is also capable of handling different sized wire reels.

It can feed the wire smoothly hence comes out without folding into the lead.  It has a duty cycle of 20% at 175 amps. It comes with a wire speed management and an infinite speed of welding to help facilitate its use.

Other Features

It is a very solid machine with a great weld penetration which makes wire function feed motor easy.  It however does not come with any long warranty period despite being an affordable machine. It is a perfect machine for anyone who is in need of a decent machine for use at home.

Pros

  • Produces tidy welds
  • Perfect for the hobbyists
  • Comes together with an aluminum spool gun
  • Quite affordable machine

Cons

  • Low performance
  • Not suitable for daily use

5. Hobart 300349 DP-3545-20 Spool Gun

Salient Feature

  • Voltage: 115 V
  • Style Spool Gun: Screw-style
  • Installation Method: MIG Welding
  • Cable Length: 20 ft
  • UNSPSC Code: 23270000
  • Field of Application: Aluminum
  • Includes Component : Spool Gun, 20 ft cable & Argon Regulator

This Hobart 300349 DP-3545-20 Spool Gun comes packed with great features. It was specifically made for lightweight welding. Its compact design makes it a perfect spoon gun welder for MIG welding.

Features

It measures 11.5 by 2.25 by 8 inches and has a weight of around 8 pounds along with a cable assembly. It is very easy to set up this machine and can be very convenient when it comes to MIG operation that you are working on.  It does have a duty cycle of 60% at 200 amps and has a pool compartment which is well enclosed with wire roll tension adjustment for internal spool hub.  This spool gun also comes with a feed roll and contact tips for steel, stainless steel and aluminum.

Other Features

It comes with a one year warranty period and does have accessible drive rolls, a 20 ft cable, spool hub tension adjustment and contact tips for the aluminum, steel and stainless steel. Setting up this spool gun is simple and easy. All one has to do is remove the MIG standard gun and place the DP-3545-20 before switching it on.

Pros

  • It works quite faster
  • Easy to set up
  • It is of compact design and lightweight
  • Made using sturdy and durable materials

Cons

  • Can leave hump weld
  • When you first install it, you can encounter lots of trouble

6. Klutch 150 Spool Gun Kit

Salient Feature

  • Voltage: 115 V
  • Style Spool Gun: Tweco-style
  • Installation Method: MIG Welding
  • Cable Length: 10 ft
  • UNSPSC Code: 23270000
  • Field of Application: Aluminum
  • Includes Component : 10 ft cable, spoon gun

This Klutch 150 Spool Gun Kit comes with an inverter based system which makes it unique from the other welders in the market. Its innovative system is what is behind its less power supply need. It can also handle any power fluctuations ensuring a smarter and smooth welding experience.

Features

This Klutch 150 Spool Gun Kit is quite lightweight weighing just 37.1 pounds hence, very easy to carry around. It can weld stainless steel and mild steel as it has a great welding control with an amperage of between 40 to 140 amps.  You need not to worry about it welding aluminum as it comes with a very great spool gun.  It can easily weld material measuring ¼ inches to ½ inches in thickness without the thermal shutting off or going crazy.

Other Features

It is possible to use this Klutch 150 Spool Gun Kit with or without a protecting gas. This package has a 10 ft ground cable, gas horse, spot timer, MIG torch, regulator and a spot timer. It also comes with a three years warranty period that is one of the highest.

Pros

  • Comes with a three year warranty period
  • It is of high performance
  • Can be used with or without the protective gas
  • Has a very great welding control

Cons

  • There is no provision for a plug.

7. Miller Electric 301272 Spool Gun

Salient Feature

  • Voltage: 115 V
  • Style Spool Gun: Spool Gun
  • Installation Method: MIG Welding
  • Cable Length: 20 ft
  • UNSPSC Code: 27000000
  • Field of Application: Aluminum
  • Includes Component : 20 ft cable & gas hose

This Miller Electric 301272 Spool Gun is one of the most reliable and innovative   spool gun available in the market.  It is suitable equipment for both the novice and experienced users.

Features

This Miller Electric 301272 Spool Gun features a completely newly designed drive system which has been made using cast aluminum and not low quality plastic products. This will help ensure it is rugged enough and capable f withstanding lots of abuse. It also comes with an angled design and calibrated tension knob to help the system feed the wire in an even and smooth way.

The Miller Electric 301272 Spool Gun is one of the cleanest weld starts you will come across in the market. It uses a fan on demand system that will allow you save on the cost of electricity and prolong your machine’s lifespan.

It is a very powerful welder that you can use on either the 120V or the 240 V outlets. It makes it possible for the user to weld in different environments. Its wide voltage ranges offers more flexibility on power which makes it possible for the machine to be used on a simple household project.

Other Features

Switching from one voltage to another is quite simple and fast. It comes with a multi voltage plug that is an important adapter.

Pros

  • It is lightweight in design
  • Uses an inverter base technology
  • Has an efficient cooling system
  • Has a wide voltage range

Cons

  • Quite expensive
  • Some of its parts are a bit flimsy

What is the purpose of a spool gun?

The spool gun has been well designed to help connect to the HIT140/MMIG140 only. It can be used on feeding wires that are very difficult to feed using the standard MIG torch. In most cases, this is usually used for aluminum wires although any wire type can be used. The spoon guns will help in improving the feed ability of the aluminum wire.

How do you weld Aluminum with a spool gun?

Here are steps that will guide you on welding aluminum using a spool gun.

  • Clean the Metal

It is possible to weld at times without cleaning the metal especially when it is new or does not have any residues on it. It is always appropriate to start your aluminum welding using a spool gun by cleaning the metal using an angle grinder or a wire brush.

  • Welding Angle

In most cases, a 10-15 degree angle will ensure a job is effectively done.   As is the case with most welding projects, when you get this wrong, there could be more problems with the weld than you could experience when welding steel.  Attention to detail is very important when you are maintaining the right angle.

  • Set Wire speed and voltage for Aluminum welding

The wire speed and amperage are the first places you can start with your adjustments before you start welding aluminum. Lots of heat and too much wire will do a number on the weld and leave you with lots of mess to clean up. Make use of the chart that comes with the welder so as you can experiment with a few different voltages and wire speed settings before you start working.

  • Use a Gas Flow for Aluminum Mig welding

In case the arc is hissing too much or jumping around, there is a better chance you will have to adjust the gas flow shielding. Lots of shielding gas will always cool off the weld puddle.

  • Check metal temperature for welding Mig Aluminum

You can consider preheating the aluminum as it will give you a neater and cleaner weld. In case you are working on a cold climate, ensure you consider preheating the metal before you strike the arc.

  • Keep testing the settings

Even the experts will always have to conduct a number of tests to ensure they get the right welding setting. No one will want to cover their welding work with burn or spatter. This is why you need to always test the gas flow, stick out length, and burn up speed and the amperage.

How To Choose The Best Spool Gun For Aluminum Welding?

There are a number of things you need to consider when shopping for the best spool gun for aluminum welding in the market. 

  • Material Quality

Before you settle on any spool gun, it is important that you check on the quality of materials used in making the product. For instance, a higher quality of MIG welder will work quickly and more efficiently.

Top quality material is made using heavy duty materials. Some of the quality materials used in making a spool gun is stainless steel, aluminum, iron and mild steel.

  • Wire Size

It is highly advisable that you are aware of the wire size and the type of material used in making the wire. Determining the width and length of the wire is important. It does not matter if you are a hobbyist or a professional, it is important that you always have a great idea about the wire speed, diameter and type of material used.

  • Power Supply

The Spool guns are known to work by consuming power while feeding wire electrode to help in creating heat that will attach the metal. Power supply is usually categorized into two types. There is the input and output power. Most of the spool guns are known to use constant voltage power supply.

The industry level welding will require higher input power to enable it melt the heavy duty metals quickly. Considering the material thickness, input power will need to be adjusted always.

  • Duty Cycle

Duty cycle refers to the time limit that will help prevent overheating. Overheating is capable of over melting and changing the metal. Depending on the type of metal and heat amount, always check if you can adjust the heat and set a time limit.  The duty cycle feature will help you to automatically control the temperature. In most cases, an ordinary pool gun will have a 10 minutes duty cycle.

  • Controls

Any typical spool gun will comprise of a power cable, control switch and an electrode conduit. Always go for a spool gun that has fewer manual control and more controls that are automatic which will enable you have an easier work.

Most of the machines today have been designed to have more of the automatic controls that can work fast and are simple to use. In case you are a newbie, the automatic controls will be very easy to use and help save your time and energy.

  • Size and Weight

Size and weight of the spool gun do matter as it will determine if the machine is versatile and portable. It is advisable to always go for a machine that weighs lesser if you will be using it from your home or on simple projects. However, the industrial level spool guns need to be made of heavy duty materials which make them quite heavy.

Go for a machine of reasonable size which you can easily transport and store in case it is not in use.

  • Durability

No one will want to get back to the market a few weeks after spending lots of cash to get a new best spool gun for aluminum welding. It is important that you check on how durable the machine is. You can determine this by looking at the quality and type of materials used in making it.

Price and warranty period will also help tell if the spool gun is durable or not.  Spool guns that are very cheap in most cases never last for long due to the quality of materials used in making them. Spool guns with short warranty period are in most cases not that durable.

  • Wire Feed Speed

The spool gun wire feed speed is an important aspect since it decides how accurate and fast welding can be done. Different welders are known to have different wire feed speed.  You can always make your choice depending on your preferences.

Conclusion

We do hope that our best spool gun for aluminum welding review has been of great help to you. For sure, there is no shortage of top spool gun machines in the market. In our top 7 review, be sure you will be satisfied with any of the products and that you will have a great experience for every machine you settle for.

Thanks for taking your time and going through this review. In case of any question, suggestion or comment, kindly feel free to leave your comment below.

FAQ

Do you have to use a spool gun to weld aluminum?

For successful welding of aluminum, you need a very stable arc.  Spool gun do have a short feed distance that offers a reliable and steady feet. Having a smooth feed to weld is one of the key things behind getting a smooth arc.

What welder is best for aluminum?

MIG welding is widely known to be best when it comes to dealing with thinner aluminum sheet gauges. This is due to the amount of heat required.  When you are selecting a shielding gas, 100% argon is considered as the best for MIG welding aluminum.

What gas do I use for aluminum spool gun?

Since aluminum is a non ferrous metal, it does require a 100% argon shielding gas.

Can you use 75/25 to weld aluminum?

75/25 basically means 75% of Argon while the remaining 25% is CO2.  Pure argon will always give perfect results when it comes to aluminum welding. It is very possible to use 75/25 in welding on aluminum.

How many amps do you need to weld aluminum?

When welding aluminum, it is advisable that you use 1 amp for every 0.001 of material thickness. This means that the material welding base is 1/8 inches thick will need about 125 amps.

What polarity do you need to stick weld aluminum?

When it comes to stick welding of aluminum, the DC+ polarity is most often used. It will always produce a better bead profile with a much higher penetration level.

Can all TIG welders weld aluminum?

The most basic method of welding aluminum is TIG welding. Any TIG welder is capable of welding aluminum. 

Last Updated on May 24, 2021 by weldinghubs

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