How To Weld Aluminum With Lincoln 180. If you will need to weld a broader range of aluminum thicknesses consider investing in the 230v machine. Other options are second best but a good job can be done with them depending on the metal thickness and application.
The easiest solution is to buy a spool gun designed to work with aluminum welding. I has 025 solid core now and was thinking about going up to 035-----025 is fine and probably the best choice for really thin metal like auto body panels. The recommended electrode angle of travel is 5 to 15 degrees.
This choice requires you to replace regulators designed for CO2 but you dont have to buy new hoses.
I spent 20 years in the aluminum railing business and have welded pretty well anything to anything. A brush you only use on Aluminum. Aluminum oxide on the surface of the material melts at 3700 F while the base-material aluminum. Mig welding aluminum is not as hard as TIGing aluminum but its preaty hard to get a decent weld with a mig.