Aluminum Welding System offers one-knob synergic control.

Press Release Summary:

Designed for MIG and pulsed MIG aluminum applications, AlumaFeed Synergic System consists of AlumaPower 350 MPa synergic power supply providing 5-425 A/10-38 V, XR AlumaFeed wire feeder/control module, and XR-Aluma-Pro or XR-Pistol Grip gun. Profile Pulse(TM) pulsed MIG output creates stacked dime weld bead appearance without torch manipulation, while Hot Start(TM) function minimizes incomplete fusion or cold lap at beginning of weld.

Original Press Release:

New AlumaFeed(TM) Synergic Aluminum Welding System Simplifies Operator Training, Improves Performance

Designed exclusively for MIG and pulsed MIG aluminum applications, the AlumaFeed System features Miller's new Profile Pulse(TM) pulsed MIG output, which creates a "stacked dime" weld bead appearance without torch manipulation. Highlights/Key Facts
o Long reach and lightweight portability for large aluminum weldments: boats, ships, yachts, emergency vehicles, trucks and trailers, recreational vehicles and general aluminum fabrication.
o Durable design for consistent, reliable performance in high-volume, high arc-on time applications using .030- to 1/16-in. diameter aluminum wire.
o True torque feed motor, push-pull gun system provides Miller's best-ever aluminum feeding performance for maximum productivity. APPLETON, Wis., July 3, 2009-Miller Electric Mfg. Co. today 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(TM) output. The AlumaFeed System consists of the AlumaPower 350 MPa synergic power supply (an 80-lb. 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 lbs.) and the XR-Aluma-Pro or XR-Pistol Grip gun (air- and water-cooled models available, in 25- or 30-ft. length options).The system is designed for Mig Aluminum applications only, eliminating unneeded controls and complexity that can lead to unintended errors. With optional extension cords, an operator can take the wire feeder up to 100 ft. away from the power source, providing an extended reach that improves production efficiency when welding inside hulls or tanks, or maneuvering around large weldments. Simpler and Better
The AlumaFeed System simplifies and improves aluminum welding through a combination of features:
o "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, thus reducing training time.
o In addition to traditional pulse, 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.
o Hot Start(TM) 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. These can be set manually or use the preset auto mode or can be turned off from the front of the AlumaFeed panel.
o 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.
o The system includes a parameter range and system lock function that can be used to ensure that all operators and all shifts weld according to specified procedures, helping ensure consistency and quality. Links
AlumaFeed Product Page: AlumaFeed Spec sheet: Product Manager Quote
"In head-to-head comparisons, high-volume manufacturers in the emergency vehicle and shipbuilding industries stated that the AlumaFeed Synergic Aluminum Welding System offered the best performance and simplest operation of any industrial MIG aluminum system."
-Mike Vandenberg, product manager, Miller Electric Mfg. Co. "Miller designed the AlumaFeed Synergic Aluminum Welding System exclusively for MIG welding aluminum. By focusing on one thing and doing it very well, we achieve a degree of simplicity and performance not possible with other systems."
-Mike Vandenberg, product manager, Miller Electric Mfg. Co. Additional Information
Built to Last
Miller designed the AlumaFeed Synergic Aluminum Welding System specifically to withstand years of welding in high-volume, high arc-on time applications, such as those in the boat, ship, yacht, emergency vehicle, truck and trailer, recreational vehicle industries. The XR-AlumaFeed wire feeder incorporates an improved wire feeder-gun connection uses a bushing to capture the gun's power pin, providing ruggedness and durability while also ensuring correct drive roll alignment. An enhanced drive roll tensioning design prevents wire slippage and deformation and features a numeric scale for setting the correct drive roll tension (incorrect tension is a leading source of feeding problems). Other features of the new feeder include a set-up guide on the inner panel of the feeder to help guide the operator, easy-to-read digital displays, dual schedule control and 4-Step trigger operation. The AlumaPower 350 MPa power source incorporates Miller's newest generation of software and controls which together provide operators with greater weld puddle control and arc stability. To ensure reliability and quality in industrial applications, Miller uses primary power management and conversation technology (AutoLine) the same found in its XMT® 350 inverter (which is regarded as one of the most reliable welders available). About Miller
Miller Electric Mfg. Co., headquartered in Appleton, Wis., is a leading worldwide manufacturer of Miller brand arc welding equipment and is a wholly owned subsidiary of Illinois Tool Works Inc. (NYSE: ITW). For more information, visit Miller's Web site at, call 1-800-4-A-Miller (800-426-4553), e-mail, fax 877-327-8132, or write to Miller Electric Mfg. Co., P.O. Box 100, Lithonia, GA 30058.

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