Below are some of the most pressing details to keep in mind when using the stick welding method. The best method for maximum control over the aluminum welding process is AC alternating current TIG tungsten inert gas using a helium or argon mix.
This is the cleanest and slowest technique, ensuring that there is very little mess left behind making it the perfect candidate for welding thin aluminum, especially. DC direct current TIG welding is acceptable for aluminum workpieces as well.
However, this technique is recommended more for thicker workpieces due to the greater depth of penetration. Thirdly, there is MIG metal inert gas welding. This is significantly faster than TIG, but with some compromises. You will have a reduced extent of control over the process since the base metal will not melt without the addition of a filler metal.
Still, the process will not require either a push-pull or spool gun if the following elements are properly adjusted:. It is possible to stick weld aluminum, and, possibly to the surprise of many, it can be done even with a DC stick welder it works better than you might expect!
Before you get started, be aware that, when using the aluminum stick, you will notice that the flux is inclined to spatter. Of course, various types of maintenance alloys will behave differently, and you may not have this experience with the types of sticks you wind up using.
This extent of variation is naturally, due primarily to the flux composition. Fortunately, there are steps you can take to make the process go a bit more smoothly. Inexpensive and easy to perform in a wide variety of environments, this welding technique is often reserved for small fabrication shops and hobby welders but can be used to weld aluminum together smoothly. The key is to use a more powerful, direct current welder and an aluminum-coated electrode.
By welding quickly, without giving the metal too much contact with the arc, the aluminum can be bound quickly. Gas metal arc welding GMAW , informally called Heliarc welding, is a process of welding that adds inert gas, such as argon or helium, in order to ensure that oxidation does not occur during the melting process. To weld aluminum with this method, it is best to preheat the metal to no more than degrees Fahrenheit before beginning the weld.
By using argon gas and pushing rather than pulling the welding gun away from the weld puddle, aluminum can be bound without much trouble. Blake Flournoy is a writer, reporter, and researcher based out of Baltimore, MD. Working independently and alongside professors at Goucher College, they have produced and taught a number of educational programs and workshops for high school and college students in the Baltimore area, finding new ways to connect students to biology, psychology, and statistics.
They have never seen Seinfeld and are deathly scared of wasps. By recognizing these differences we can adjust accordingly but it requires skill. For best results preheat the metal before you start the weld.
Look at the settings with your welder about how to switch over to a spool gun. You will need aluminum wire to weld aluminum. Popular aluminum wires are , and For welding or to themselves use Use or for For the full chart of specifications see this chart from Hobart.
When you MIG weld steel you might get away with a bit of dirt on the metal, but with aluminum you really need to make sure that the metal is clean. In sum, here are some of the most common factors that make aluminum challenging to weld: Oxidation : On top of aluminum sits an aluminum oxide layer, which melts at a significantly higher temperature than aluminum.
Melting through this layer requires high heat, however, the welder must be careful to not burn holes in the aluminum underneath. Porousness : In its molten state, aluminum absorbs hydrogen quicker the more it heats up. This hydrogen separates out as the metal returns to a solid form, which can leave behind bubbles in the material, causing the metal to become porous and weak.
Impurities : As aluminum is very sensitive, there are several ways it can become contaminated by dirt, air and water during the welding process.
Aluminum can become contaminated by air that reaches the weld because of poor shielding or excessively long arcs. Hydrogen can come from many sources, such as moisture in electrode fluxes, humid air, damp weld joints and more. Thickness : Welding aluminum involves working with different material thicknesses. Welders must know how to avoid burning through thinner material while also penetrating thick material enough to create a strong weld.
Use a stainless steel wire brush used exclusively for aluminum to remove surface oxides. This can also be done with a strong alkaline or acid. Always be sure to rinse and fully dry the part before welding. This will prevent dirt or grit from contaminating the joint. Always keep your aluminum dry and stored at room temperature. Tips for MIG welding: Prepare your push-pull wire feed Clean your aluminum, remove any oxide and file the edges that will be joined Avoid pulling while welding—instead, push at a 10 degree to 15 degree angle Use multiple pass straight beads to improve the overall appearance of the weld and help to avoid defects Use a heat sink, which will absorb extra heat and allow you to weld slower Other Ways to Weld Aluminum While MIG and TIG are commonly used methods for welding aluminum, there are several other types of welding that can be used: Laser beam and electron beam welding : Beam welding techniques are commonly used for aluminum.
Electron beam welding has a very precise heat affected zone that can be easily controlled, which makes it great for aluminum. Laser beam welding is great for fast, clean welds and is ideal for materials sensitive to cracking, such as aluminum.
Resistance welding : This type of welding joins metals by applying pressure and passing current through the metal areas being joined. It can be used for aluminum, however the welder must be aware of the high thermal and electrical conductivity of this metal.
Shielded metal arc welding SMAW : This type of welding could be used to weld aluminum, but is not recommended. In some cases, it is used to repair cast aluminum using a constant current equipment with an aluminum electrode using electrode positive polarity. Not wearing the proper PPE : Speaking of dangers, welding aluminum or any kind of material is inherently dangerous.
This is key to a long, successful career in the industry. Failing to prepare : Preparation is key—both for the welder and the material being welded. Always be sure to properly clean your aluminum and store it correctly before beginning your weld.
Additionally, make sure to prepare yourself by studying the art of aluminum welding and educating yourself on the craft. Never jump into anything until you are adequately prepared. Ignoring minor details : The most successful welders will tell you that detail is everything. In this industry, the smallest misstep can lead to a complicated error—especially with aluminum welding. Always pay attention to every detail and double check your work, as this will benefit your customers and your career in the long-run.
Not being patient : Learning to weld aluminum takes time. Keep practicing and stick with it—your hard work and persistence will pay off in the end! While aluminum can be difficult to work with, this material offers several key benefits: Lightweight : When compared to steel, aluminum has a better strength-to-weight ratio and becomes stronger rather than brittle with decreasing temperature.
This makes it a great choice for projects that require strength, yet need to remain lightweight. Non-corrosive : While oxidation creates challenges during the welding process, this quality is also a benefit to using aluminum, as it is non-corrosive.
Recyclable : Aluminum is cost efficient and recyclable, which is one of the reasons it has become increasingly popular. Appearance : Aluminum effectively absorbs paint and sealant, so it is often chosen for its cosmetic qualities. Looking for Welding Training Courses?
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