GYS Pulsed MIG Welders for Aluminum

What is a GYS pulse MIG welder?

Pulsed MIG welders have transformed the welding industry, enhancing control and efficiency over traditional MIG welders. Pulsing utilises a unique technique using a pulsing current for a more precise and controlled weld.

GYS have embraced this technology and offer a range of Pulsed MIG welders suitable for the automotive repair and light fabrication sectors. offer a unique welding technique that uses a pulsing current to produce a more precise and controlled weld.

So, what exactly makes Pulse MIG welders stand out?  Well, unlike regular MIG welders that use a constant current, Pulsed MIG welder alternate between a high peak current and a low background current. This pulsing action allows welders to weld at lower average amperages, resulting in reduced heat input and lower distortion on the workpiece. Additionally, the pulsing current helps to minimize spatter and ensure better penetration, leading to higher-quality welds.

Pulsed MIG welders are particularly useful when welding thin materials or on projects that require precise control. The pulsing action enables welders to make smoother and more controlled welds, contributing to a clean and aesthetically pleasing finish. Moreover, this welding technique is also beneficial when working with alloys that are prone to distortion or heat damage.

Thats not to say Pulsed MIG Welding isn't suitable for welding steels because it is, in fact the advantages of pulsed steel welding mean you can weld upto 40% faster than Dip Transfer MIG Welding with greatly reduced spatter!

What's the correct machine setup for welding aluminium?

Setting up your MIG welder to weld aluminium is prone to mistakes and producing weld faults. Aluminium welding wire is a lot softer than steel welding wire and so needs to be fed through the torch using special liners and 4 roll wire feeders give a better push than single drive roller units. The setting of the wire tension is also very critical  other wise you may experience “birds nesting of the wire if a blockage occurs at the welding tip.

You can weld aluminium with a conventional transformer MIG welder although with increased spatter. This type of welding is called "Dip Transfer" and due to the nature of having to dip into the weld pool to ​create the weld, it becomes near impossible to weld thin automotive aluminium body panels.  This is where Pulsed welding comes into the fore. Pulsed welding is a technique that is specifically designed for welding aluminium. It provides a more controlled and consistent heat input, which is crucial when working with thin materials. The pulsing action allows the welder to alternate between high and low currents, reducing the risk of overheating and distortion.

When setting up a machine for welding aluminium, it is important to consider the type of welder being used. A GYS Pulsed MIG welder is an excellent choice for aluminium welding. It offers various features, including adjustable wire feed speed and voltage settings, which allow for precise control and fine-tuning of the welding process. The clear LCD enables the welder/ operator to choose and adjust the welding parameters quickly and easily.  Optimum weld settings for the main types of aluminium are already preset into the welder enabling the welder to produce quality professional welds straight out of the box.

MIG welding aluminium

​MIG welding aluminium can be a challenging yet rewarding task, especially if you have the right equipment, like a GYS Pulsed MIG Welder.  Aluminum is a lightweight metal with excellent corrosion resistance, making it a popular choice for various applications. However, its high thermal conductivity and oxide layer make it trickier to weld compared to other metals.  The oxide layer naturally forms on the surface of the aluminium to protect it from the natural atmosphere of our planet. It is a bit like a clear paint lacquer  It is there but you can't see it, and it grows like a mould covering all of the aluminium surface. You need to remove this oxide layer either before you start welding or by using a pulsed welding technique.  To manually clean use a stainless steel brush or dedicated aluminium cleaner to help eliminate any impurities that can compromise the quality of the weld. 

When it comes to MIG welding aluminium, it is crucial to have the correct settings on your  MIG welder. Aluminum requires a higher voltage and a slower wire feed speed compared to welding steel. This is because aluminium has a lower melting point and conducts heat more efficiently. Adjusting the wire speed, voltage, and gas flow will ensure proper penetration and a strong weld in dip transfer mode.  If you have Pulsed MIG Welding though aluminium suddenly becomes a lot easier to weld, especially thin aluminium. 

THE GYS Range OF Pulsed Welders

GYS NEOPULSE 220C XL MIG WELDER

The Neopulse 220C XL is a compact pulsed inverter MIG welder engineered for versatility in site work and light fabrication applications. This advanced welding system using synergic pulsed technology, allowing for precise control over the welding arc and minimising spatter

The inverter technology enables the machine to be lightweight and portable while delivering high-performance welding capabilities.  The GYS NEOPULSE 220C XL model operates on a 230V single-phase power supply, making it suitable for various workshop and on-site environments.  It features a robust design that can handle demanding welding tasks while maintaining a compact form factor for easy transportation.

Aluminum MIG wire selection

​When it comes to aluminium MIG welding, selecting the right wire is crucial for achieving optimal results. The type and quality of the wire can greatly impact the weld strength, appearance, and overall performance. One popular option for aluminium MIG welding is the GYS Neopulse 220C XL, which offers advanced features and capabilities for professional welders for site work.

Choosing the correct aluminium wire is essential to ensure a successful weld. The most commonly used aluminium MIG wire is ER4043, which is suitable for welding a wide range of aluminium alloys. This wire provides excellent flow characteristics, and good strength, and is corrosion-resistant. Another option is ER5356, which is ideal for applications that require high tensile strength and minimal post-weld cleaning.

To further enhance the welding process, both the Neopulse 220C XL and the GYS AUTOPULSE 220-M3  offer advanced technology that ensures precise control over the welding parameters. It features a pulse function that allows for better control of the heat input, resulting in reduced spatter and a more stable arc. These Pulsed MIG welders also offer synergic welding, where the welding parameters are automatically adjusted based on the selected wire type, ensuring optimal performance.

When working with aluminium MIG welding, selecting the right wire is essential for achieving quality welds. The GYS Neopulse 220C XL and GYS AUTOPULSE 220-M3  are an excellent choice for professional welders, featuring advanced technology that enhances the welding process. By choosing the appropriate aluminium wire and utilizing the capabilities of the NEOPULSE and AUTOPULSE welders you can achieve strong and visually appealing aluminium welds.

Paul Jones Director BWS Ltd, CSWIP Ive been a welding engineer for over 30 years and a welding inspector for 23 years with vast experience of welding and related topics.