Spool Gun vs Push-Pull Gun: Choosing for Aluminium MIG

Welding with aluminium can be a struggle, and there’s a lot of things that can go wrong as it’s a softer metal than steel. Because aluminium can be such a pain to work with when trying to MIG weld with it, several types of aluminium specific torches have been made to make the process easier.

Which one is going to work best for you?

What’s a Spool Gun?

A spool gun is a pistol grip style gun with a compartment for a wire spool roll to be attached directly onto the gun.

The gun also comes with its own drive rollers inside the gun, so the wire can feed from the spool, through the gun and out into the weld.

The wire only has to travel the length of the gun instead of through a 4-metre torch lead, which means there are so many less places for things to go wrong.

What’s a Push-Pull Gun?

A Push-Pull gun is a pistol grip style gun with a small, second motorised wire feeder directly in the gun.

This motor works in harmony with the feeder inside the machine, and together they achieve a smooth feed as the machine pushes the wire through the torch lead and the gun pulls it through from the other end.

A Push-Pull gun is more like a standard MIG torch than a spool gun, as the wire spool is still loaded up inside the machine and fed through the machine’s rollers and into the torch lead.

Which one should I use?

Changing wire material requires a compatible gun, liner, contact tip and drive parts, not just a roller change.

Available lead lengths and compatible machines vary by gun model. Confirm the approved combination before buying.

Despite the fact that they were made to do the same thing, there are a couple of differences to consider when you’re picking between the two.

A short wire path can reduce feeding problems, but it does not eliminate birdnesting or the need for correct setup.

Generally, a spool gun is the best choice for aluminium if you’re using it for smaller applications or you only weld aluminium occasionally.

Compare the gun's current rating at its stated duty cycle and shielding gas; it may be lower than the power source's rating.

Do not assume every spool gun or push-pull gun has the same amperage range or duty cycle.

The spool holder on the gun makes them bulkier than other guns, so you may find it harder to get into tight spots as well, as the gun’s angle is really important for a good weld.

Spool capacity is model-specific; confirm both spool dimensions and supported wire size.

Select the system for access, gun weight, run length and workload as well as price.

A Push-Pull gun, though bulky, is usually lighter and smaller than a spool gun but still heavier than a standard MIG torch. It’ll fit into small or tight spaces better than a spool gun because it doesn’t have the spool holder getting in the way.

In general, if you’re planning on doing lots of aluminium welding or welding it for long periods in one go, a Push-Pull gun is for you.

A material change may require changing or cleaning parts of the wire path. Remaining wire is not automatically waste if it can be removed and stored without damage or contamination.

Reference diagrams: UNIMIG. Original source attribution is retained.