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If the wire is solid, you will not be able to MIG weld aluminum without a shielding gas. It barely wants to feed when it's solid wire.so a hollow version would probably jam like crazy. I don't think they make a Flux Core aluminum wire. Perhaps it is a standard size, and you won't have any trouble finding one at all? Even Lowe's sells them, and those are all the same size, even though they come in several different alloys. ![]() They are small, somewhere between 4 to 6 inches in diameter. Chances are that it will be thinner than.035 - I don't know much about the little spools that fit those machines, but they all seem to be about the same size at the welding shop. There you might find what wire diameter range you can use. You might have luck going to the Lincoln and Miller websites, and looking up some owner's manuals for their 125 amp machines. A 125 amp MIG welder only has the power to melt wire up to a certain thickness. ![]() So, be sure you're buying a spool of flux core wire, and not solid wire, if you do not use gas. It has a flux inside the hollow wire, which will protect the weld from Oxygen, like the gas would. Here are some facts to keep in mind and possibly research: - If your welder is not going to be using a sheilding gas, you MUST use FLUX CORE wire when welding steel. Best Answer: I own a MIG welder, but mine is big, uses sheilding gas, and takes #44 spools.
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