Aluminum Welding Guide: Tips & Techniques – Weld Guru

Affiliate Disclaimer : This post may contain links that will earn us a commission at no cost to you. This helps keep Weldguru a complimentary resource for our readers. Aluminum is a lightweight, soft, low-strength metal that can easily be cast, forged, machined, formed and welded.
Unless alloyed with specific elements, it is desirable entirely in low-temperature applications .
Aluminum is promptly joined by welding, braze, and soldering.

In many instances, aluminum is joined with the conventional equipment and techniques used with early metals. however, specialized equipment or techniques may sometimes be required .
The alloy, joint configuration, strength required, appearance, and cost are factors dictating the choice of process. Each process has certain advantages and limitations .


Aluminum is alight gray to silver in discolor, very bright when polished, and boring when oxidized .


A fracture in aluminum sections shows a smooth, bright structure. Aluminum gives off no sparks in a discharge examination, and does not show red anterior to melting. A heavy film of white oxide forms immediately on the fade surface .
Aluminum is light in weight and retains good ductility at subzero temperatures. It besides has high gear resistance to corrosion, commodity electric and thermal conduction, and senior high school coefficient of reflection to both heat and light .
Pure aluminum melts at 1220ºF ( 660ºC ), whereas aluminum alloys have an approximate fade range from 900 to 1220ºF ( 482 to 660ºC ). There is no color change in aluminum when heated to the welding or braze range .
Its combination of lightweight and gamey military capability make aluminum the moment most popular metallic element that is welded .
single wire mig aluminum welding

Aluminum five Steel Welding

One cause aluminum is different from steels when weld is that it does not exhibit color as it approaches its liquescent temperature until it is raised above the thaw luff, at which time it will glow a dull red .
When soldering or brazing aluminum with a common mullein, flux is used. The flux will melt as the temperature of the basal metallic approaches the temperature required. The liquefy dries out first, and melts as the base metallic element reaches the correct work temperature .
When torch welding with oxyacetylene or oxyhydrogen, the come on of the base metallic will melt beginning and assume a characteristic wet and glazed appearance. ( This aids in knowing when welding temperatures are reached. ) When welding with gas tungsten arc or gas metal discharge, color is not as important, because the weld is completed before the adjoining area melts .

Molten Aluminum Filler

molten aluminum filler

Welding Properties and Alloys

Aluminum and aluminum alloys can be satisfactorily welded by metal-arc, carbon-arc, and other arc welding processes. Pure aluminum can be alloyed with many other metals to produce a wide range of physical and mechanical properties .
The means by which the alloy elements strengthen aluminum is used as a basis to classify alloy into two categories : not heat treatable and heating system treatable. Wrought alloys in the form of sheet and denture, tubing, extruded and rolled shapes, and forgings have alike join characteristics regardless of the form .
Aluminum alloys are besides produced as castings in the imprint of sand, permanent model, or die castings. substantially the lapp weld, braze, or soldering practices are used on both cast and work alloy .
Die castings have not been wide used where weld construction is required. however, they have been adhesively bonded and to a limited extent soldered. late developments in vacuum fail casting have improved the choice of the castings to the target where they may be satisfactorily welded for some applications .
The star advantage of using arch weld processes is that a highly reduce heating zone is obtained with the arc .
For this reason, excessive expansion and distortion of the metallic element are prevented .
Aluminum possesses a issue of properties that make welding it different than the welding of steels. These are : aluminum oxide airfoil coating ; high thermal conduction ; high thermal expansion coefficient ; abject liquescent temperature ; and the absence of coloring material switch as the temperature approaches the melt point .
The normal metallurgical factors that apply to other metals apply to aluminum american samoa good .
Aluminum is an active metallic that reacts with oxygen in the air to produce a hard, reduce film of aluminum oxide on the airfoil .
The melting distributor point of aluminum oxide is approximately 3600ºF ( 1982ºC ) which is about three times the melting point of pure aluminum ( 1220ºF ( 660ºC ) ). In addition, this aluminum oxide film absorb moisture from the air, particularly as it becomes thick .
moisture is a informant of hydrogen, which causes porosity in aluminum welds. hydrogen may besides come from anoint, paint, and soil in the dyer’s rocket area. It besides comes from the oxide and extraneous materials on the electrode or filler telegram, ampere well as from the base metallic element. Hydrogen will enter the weld pool and is soluble in fade aluminum. As the aluminum solidifies, it will retain much less hydrogen .
The hydrogen is rejected during hardening. With a rapid cooling rate, free hydrogen is retained within the weld and will cause porosity. Porosity will decrease weld persuasiveness and ductility, depending on the measure .

Welding Rods

Stick welding aluminum ( aluminum welding rods ) are available at a thickness that is approximately 1/8″ of sword. It is an excellent choice for repairing tanks and pipes in the playing field. besides, a good choice when working in airy conditions. It is not for precise work .
The downside of using aluminum welding rods is the need for a solid sum of commit. There is besides a flux issue. the flux burns aggressively and is hard to remove. It besides burns through paint .
There are superior alternatives to aluminum welding rods such as wire feed weld .
Read : Can you stick weld aluminum ?

Aluminum Alloy Numbering

many alloys of aluminum have been developed. It is important to know which debase is to be welded. A organization of four-digit numbers has been developed by the Aluminum Association, Inc., to designate the diverse cultivate aluminum alloy types .
This system of alloy groups is as follows :

  1. 1XXX series. These are aluminums of 99 percent or higher purity which are used primarily in the electrical and chemical industries.
  2. 2XXX series. Copper is the principal alloy in this group, which provides extremely high strength when properly heat treated. These alloys do not produce as good corrosion resistance and are often clad with pure aluminum or special-alloy aluminum. These alloys are used in the aircraft industry.
  3. 3XXX series. Manganese is the major alloying element in this group, which is non-heat-treatable. Manganese content is limited to about 1.5 percent. These alloys have moderate strength and are easily worked.
  4. 4XXX series. Silicon is the major alloying element in this group. It can be added in sufficient quantities to substantially reduce the melting point and is used for brazing alloys and welding electrodes. Most of the alloys in this group are non-heat-treatable.
  5. 5XXX series. Magnesium is the major alloying element of this group, which are alloys of medium strength. They possess good welding characteristics and good resistance to corrosion, but the amount of cold work should be limited.
  6. 6XXX series. Alloys in this group contain silicon and magnesium, which make them heat treatable. These alloys possess medium strength and good corrosion resistance.
  7. 7XXX series. Zinc is the major alloying element in this group. Magnesium is also included in most of these alloys. Together, they form a heat-treatable alloy of very high strength, which is used for aircraft frames.


Since aluminum has a capital affinity for oxygen, a film of oxide is constantly confront on its surface. This film must be removed anterior to any attempt to weld, braze, or solder the material. It besides must be prevented from forming during the join routine .
In homework for aluminum for welding, braze, or solder, scratch this film off with a sharply tool, wire brush, emery paper, or similar means. The consumption of inert gases or a generous application of flux prevents the shape of oxides during the connect work .
Aluminum and aluminum alloys should not be cleaned with caustic sodium carbonate or cleaners with a ph above 10, as they may react chemically .
The aluminum oxide film must be removed prior to welding. If it is not wholly removed, small particles of un-melted oxide will be trapped in the weld pool and will cause a decrease in ductility, miss of fusion, and possibly weld snap .
The aluminum oxide can be removed by mechanical, chemical, or electrical means. mechanical removal involves scraping with a sharp creature, emery paper, wire brush ( stainless steel steel ), filing, or any other mechanical method acting .
Chemical removal can be done in two ways. One is by use of clean solutions, either the engrave types or the nonetching types. The nonetching types should be used merely when starting with relatively clean parts, and are used in conjunction with other solvent cleaners. For better clean, the etching type solutions are recommended, but must be used with care .
When dip is employed, hot and cold wash is highly recommended. The etching type solutions are alkaline solutions. The time in the solution must be controlled indeed that besides much etch does not occur .

Chemical Cleaning

Chemical cleanse includes the practice of welding fluxes. Fluxes are used for gasoline welding, braze, and soldering. The coating on report aluminum electrodes besides maintains fluxes for cleaning the base metal. Whenever etch clean or flux clean is used, the flux and alkaline etch materials must be wholly removed from the weld area to avoid future corrosion .

Electrical Oxide Removal System

The electric oxide removal system uses cathodic bombing. Cathodic barrage occurs during the half motorbike of alternating current boast tungsten arc welding when the electrode is positive ( rearward polarity ) .
This is an electric phenomenon that actually blasts away the oxide coating to produce a clean surface. This is one of the reasons why AC gasoline tungsten arc welding is so popular for welding aluminum .
Since aluminum is indeed active chemically, the oxide film will immediately start to reform. The time of buildup is not extremely flying, but welds should be made after aluminum is cleaned within at least 8 hours for choice weld. If a longer clock time period occurs, the quality of the weld will decrease .

Thermal Conductivity

Aluminum has a high thermal conduction and low liquescent temperature. It conducts heat three to five times equally flying as sword, depending on the specific debase .
More heat must be put into the aluminum, even though the dissolve temperature of aluminum is less than half that of steel. Because of the high thermal conduction, preheat is much used for welding dense sections. If the temperature is besides gamey or the prison term time period is besides farseeing, weld articulation strength in both heat-treated and work-hardened alloys may be diminished .
The preheat for aluminum should not exceed 400ºF ( 204ºC ), and the parts should not be held at that temperature longer than necessary. Because of the senior high school heat conduction, procedures should utilize higher speed welding processes using high heat input. Both the gas tungsten arc and the gas metallic element discharge processes add this necessity .
The high heat conduction of aluminum can be helpful, since the weld will solidify very cursorily if heat is conducted away from the weld highly fast. Along with surface tension, this helps hold the weld metallic element in put and makes all-position welding with boast tungsten discharge and natural gas alloy arc welding virtual .
The thermal expansion of aluminum is twice that of sword. In summation, aluminum welds decrease about 6 percentage in volume when solidifying from the melt department of state. This change in dimension may cause aberration and crack .

Aluminum Plate Welding

For aluminum plate weld, because of the difficulty of controlling the bow, border and fillet welds are unmanageable to produce in plates less than 1/8 in. ( 3.2 millimeter ) midst. When welding plate heavier than 1/8 in. ( 3.2 millimeter ), a joint prepared with a 20 degree bevel will have military capability equal to a dyer’s rocket made by the oxyacetylene process .
This weld may be porous and unsuitable for liquid-or airtight joints. Metal-arc welding is, however, particularly suitable for big material and is used on plates up to 2-1/2 in. ( 63.5 millimeter ) midst .

Current and polarity settings

The current and mutual opposition settings will vary with each manufacturer ’ s type of electrodes. The mutual opposition to be used should be determined by test on the joints to be made .

Plate edge preparation

In general, the design of weld joints for aluminum is quite consistent with that for sword joints. however, because of the higher fluidity of aluminum under the weld arc, some significant general principles should be kept in take care. With the lighter gauges of aluminum sheet, less furrow spacing is advantageous when weld dilution is not a factor .
The master factor is joint planning. A specially designed V rut is excellent where weld can be done from one side only and where a placid, penetrating bead is desired. The effectiveness of this especial design depends upon surface tension, and should be applied on all material over 1/8 in. ( 3.2 millimeter ) midst .
The bottom of the particular V groove must be wide enough to contain the root communicate wholly. This requires adding a relatively large total of filler admixture to fill the rut .
excellent control of the penetration and sound ancestor sink welds are obtained. This edge preparation can be employed for welding in all positions. It eliminates difficulties due to burn-through or over-penetration in the overheat and horizontal weld positions. It is applicable to all weldable base alloys and all filler admixture .

Aluminum MIG Welding

aluminum mig welding

Gas Metal-Arc ( MIG ) Welding ( GMAW )

This fast, adaptable process is used with direct stream revoke mutual opposition and an inert accelerator to weld heavier thicknesses of aluminum alloys, in any military position, from 1/016 in. ( 1.6 millimeter ) to several inches thick. TM 5-3431-211-15 describes the process of a distinctive MIG weld plant .

Shielding Gas

Precautions should be taken to ensure the accelerator harbor is highly effective. Welding grade argon, helium, or a mix of these gases is used for aluminum welding. Argon produces a smooth and more stable bow than helium. At a specific current and arc distance, helium provides deeper penetration and a hot discharge than argon .
Arc electric potential is higher with helium, and a given change in arch length results in a greater change in discharge electric potential. The bead profile and penetration form of aluminum welds made with argon and helium disagree. With argon, the drop profile is narrower and more convex than helium. The penetration form shows a deep cardinal department .
helium results in a flat, wider drop, and has a broader under-bead penetration radiation pattern. A mix of approximately 75 percentage helium and 25 percentage argon provides the advantages of both shielding gases with none of the undesirable characteristics of either .
penetration traffic pattern and bead contour show the characteristics of both gases. Arc constancy is comparable to argon. The slant of the artillery or blowtorch is more critical when welding aluminum with inert shielding gas. A 30º leading locomotion slant is recommended .
The electrode electrify peak should be oversize for aluminum. table 7-21 provides weld procedure schedules for gas metal-arc welding of aluminum .

GMAW Aluminum Weld

gmaw aluminum weld

Aluminum Welding Technique

The electrode wire must be clean and jerk. The arch is struck with the electrode wire protruding about 1/2 in. ( 12.7 millimeter ) from the cup .
A frequently used technique is to strike the arc approximately 1.0 in. ( 25.4 millimeter ) ahead of the beginning of the weld and then quickly bring the arc to the weld starting detail, reverse the direction of travel, and proceed with normal weld. alternatively, the discharge may be struck outside the weld groove on a start pill .
When finishing or terminating the weld, a alike drill may be followed by reversing the commission of weld, and simultaneously increasing the speed of welding to taper the width of the mellow pool prior to breaking the arc. This helps to avert craters and crater crack. Runoff check are normally used .
Having established the arc, the welder moves the electrode along the joint while maintaining a 70 to 85 degree forehand angle proportional to the work .
A string bead proficiency is normally preferred. Care should be taken that the forehand slant is not changed or increased as the end of the weld is approached. Arc travel accelerate controls the bead size .
When welding aluminum with this procedure, it is must authoritative that high travel speeds be maintained. When welding consistent thicknesses, the electrode to work angle should be equal on both sides of the weld .
When welding in the horizontal placement, best results are obtained by pointing the artillery slenderly up. When welding chummy plates to thin plates, it is helpful to direct the arch toward the heavier part .
A flimsy backhand angle is sometimes helpful when welding thin sections to thick sections. The beginning pass of a joint normally requires a short discharge to provide the craved penetration. slightly longer bow and higher arch voltages may be used on subsequent passes.

The wire prey equipment for aluminum welding must be in good adaptation for effective electrify feed. Use nylon type liners in cable television assemblies. Proper drive rolls must be selected for the aluminum wire and for the size of the electrode telegram .
It is more difficult to push highly small diameter aluminum wires through retentive gunman cable assemblies than steel wires. For this rationality, the spool gun or the newly developed guns which contain a linear prey motive are used for the modest diameter electrode wires .
water-cooled guns are required except for low-current weld. Both the constant current ( CC ) ability source with match voltage sensing wire feeder and the ceaseless electric potential ( CV ) world power source with constant rush wire feeder are used for welding aluminum. In addition, the constant focal ratio wire self-feeder is sometimes used with the ceaseless current ability source .
In general, the CV system is preferred when welding on thin material and using all diameter electrode electrify. It provides better arch starting and rule. The CC system is preferred when welding thick material using larger electrode wires .
The weld quality seems better with this organization. The constant current power source with a chasten drop of 15 to 20 volts per 100 amperes and a constant amphetamine wire feeder provide the most static world power input to the weld and the highest weld quality .

Aluminum Welding Joint design

Edges may be prepared for welding by sawing, machine, circular plane, routing or arc ignore .

Fully-Automatic single wire MIG Aluminum Welding

aluminum single wire weld

Gas Tungsten-Arc ( TIG ) Welding ( GTAW )


The gas tungsten discharge welding ( TIG ) process is used for welding the flimsy sections of aluminum and aluminum alloys. There are several precautions that should be mentioned with regard to using this summons .

  1. Alternating current is recommended for general-purpose work since it provides the half-cycle of cleaning action. Table 7-22 provides welding procedure schedules for using the process on different thicknesses to produce different welds. AC welding, usually with high frequency, is widely used with manual and automatic applications. Procedures should be followed closely and special attention given to the type of tungsten electrode, size of welding nozzle, gas type, and gas flow rates. When manual welding, the arc length should be kept short and equal to the diameter of the electrode. The tungsten electrode should not protrude too far beyond the end of the nozzle. The tungsten electrode should be kept clean. If it does accidentally touch the molten metal, it must be redressed.
  2. Aluminum Welding Welding power sources designed for the gas tungsten arc welding process should be used. The newer equipment provides for programming, pre-and post-flow of shielding gas, and pulsing.
  3. Aluminum Welding For automatic or machine welding, direct current electrode negative (straight polarity) can be used. Cleaning must be extremely efficient, since there is no cathodic bombardment to assist. When dc electrode negative is used, extremely deep penetration and high speeds can be obtained. Table 7-23 lists welding procedure schedules for dc electrode negative welding.
  4. The Aluminum Welding shielding gases are argon, helium, or a mixture of the two. Argon is used at a lower flow rate. Helium increases penetration, but a higher flow rate is required. When filler wire is used, it must be clean. Oxide not removed from the filler wire may include moisture that will produce polarity in the weld deposit.

manual MIG Aluminum Weld

manual mig aluminum weld

Alternating Current Welding

Characteristics of Process

Aluminum welding with the natural gas tungsten-arc welding process using alternating current produces an oxide clean action .
Argon shielding gasoline is used. Better results are obtained when welding aluminum with alternating current by using equipment designed to produce a poise beckon or peer stream in both directions .
unbalance will result in loss of power and a reduction in the cleaning action of the bow. Characteristics of a stable arch are the absence of snapping or cracking, fluent arch begin, and attraction of lend filler metal to the weld puddle rather than a tendency to repugnance. A stable arc results in fewer tungsten inclusions .

MIG Manual Aluminum Weld

MIG manual aluminum weld

Aluminum Welding Technique

For manual of arms weld of aluminum with actinium, the electrode holder is held in one hand and filler rod, if used, in the other. An initial bow is struck on a starting pulley to heat the electrode .
The arch is then broken and reignited in the roast. This technique reduces the inclination for tungsten inclusions at the start of the weld. The arch is held at the starting detail until the alloy liquefies and a weld pool is established .
The administration and maintenance of a suitable weld pool is important, and welding must not proceed ahead of the pool .
If filler alloy is required, it may be added to the front or leading boundary of the pool but to one side of the center production line. Both hands are moved in unison with a flimsy backward and ahead motion along the joint. The tungsten electrode should not touch the filler rod .
The hot end of the makeweight gat should not be withdrawn from the argon shield. A curtly arc length must be maintained to obtain sufficient penetration and avoid undercut, excessive width of the dyer’s rocket bead, and attendant loss of penetration control and weld shape .
One rule is to use an arc duration approximately equal to the diameter of the tungsten electrode. When the discharge is broken, shrinkage cracks may occur in the weld volcanic crater, resulting in a defective weld .
This defect can be prevented by gradually lengthening the arch while adding makeweight metallic to the crater. then, cursorily break and restrike the discharge respective times while adding extra filler metallic element to the crater, or use a foot control to reduce the stream at the end of the weld. Tacking before weld is helpful in controlling distortion .
baste welds should be of ample size and military capability and should be chipped out or tapered at the ends before welding over .

Welding Joint Design

joint designs are applicable to the flatulence tungsten-arc weld action with minor exceptions. Inexperienced welders who can not maintain a very short bow may require a wide edge cooking, included lean, or joint spacing .
Joints may be fused with this process without the addition of makeweight metallic if the al-qaeda metal admixture besides makes a satisfactory filler alloy. Edge and corner welds are quickly made without addition of makeweight alloy and have a good appearance, but a identical close burst is all-important .

conduct Current Straight Polarity

Characteristics of the Process

This process, using helium and thoriated tungsten electrodes is advantageous for many automatic weld operations, specially in the weld of heavy sections. Since there is less tendency to heat the electrode, smaller electrodes can be used for a given welding current. This will contribute to keeping the weld bead narrow .
The use of direct stream straight polarity ( dcsp ) provides a greater inflame input signal than can be obtained with alternating current current. Greater hotness is developed in the weld pool, which is consequently deeper and narrower .


A high frequency stream should be used to initiate the arch. touch starting will contaminate the tungsten electrode. It is not necessary to form a puddle as in alternating current welding, since melting occurs the blink of an eye the arch is struck. Care should be taken to strike the bow within the weld area to prevent undesirable marking of the corporeal .
Standard techniques such as overflow tab key and foundation operated hotness controls are used. These are helpful in preventing or filling craters, for adjusting the current as the work heating system, and to adjust for a change in section thickness. In dcsp weld, the torch is moved steadily forth. The filler electrify is fed evenly into the leading edge of the weld pool, or laid on the joint and melted as the arch roves forward .
In all cases, the crater should be filled to a point above the weld bead to eliminate volcanic crater cracks. The lemniscus size can be controlled by varying makeweight wire size. DCSP is adaptable to repair work. Preheat is not required even for heavy sections, and the heat affected zone will be smaller with less distortion .

Aluminum Welding Joint designs

For manual dcsp, the concentrated heat of the arc gives excellent root fusion. Root face can be dense, grooves narrower, and build up can be well controlled by varying makeweight telegram size and change of location travel rapidly .

Square Wave Alternating Current Welding ( TIG )


A gamey frequency stream should be used to initiate the arc. touch starting will contaminate the tungsten electrode. It is not necessary to form a puddle as in alternating current weld, since melting occurs the instant the arch is struck. Care should be taken to strike the bow within the dyer’s rocket area to prevent undesirable score of the substantial .
Standard techniques such as overflow pill and foot operated hotness controls are used. These are helpful in preventing or filling craters, for adjusting the current as the work heat, and to adjust for a change in section thickness. In dcsp weld, the torch is moved steadily fore .
The filler cable is fed evenly into the leading edge of the weld puddle, or laid on the joint and melted as the discharge roves forward. In all cases, the volcanic crater should be filled to a point above the weld bead to eliminate crater cracks .
The fillet size can be controlled by varying filler wire size. DCSP is adaptable to repair oeuvre. Preheat is not required even for intemperate sections, and the heat affected zone will be smaller with less distortion .

Aluminum Welding Joint designs

For manual dcsp, the concentrated heat of the arc gives excellent etymon fusion. Root face can be thick, grooves narrower, and build up can be well controlled by varying filler wire size and travel travel rapidly .

Shielded Metal-Arc Welding

In the shield metal-arc welding work, a heavy dip or extruded flux coated electrode is used with dcrp. The electrodes are covered similarly to conventional steel electrodes. The flux coating provides a gaseous harbor around the arch and molten aluminum pool, and chemically combines and removes the aluminum oxide, forming a slag .
When welding aluminum, the process is rather limited due to arc sprinkle, erratic bow control, limitations on sparse material, and the corrosive legal action of the liquefy if it is not removed by rights .

Shielded Carbon-Arc weld

The shielded carbon-arc welding process can be used in joining aluminum. It requires flux and produces welds of the lapp appearance, firmness, and social organization as those produced by either oxyacetylene or oxy-hydrogen weld. Shielded carbon-arc weld is done both manually and mechanically .
A carbon arc is used as a beginning of hotness while filler metallic is supplied from a separate filler rod. Flux must be removed after welding ; differently severe corrosion will result .
Manual shielded carbon-arc welding is normally limited to a thickness of less than 3/8 in. ( 9.5 millimeter ), accomplished by the same method acting used for manual carbon paper arc weld of other fabric. joint readiness is like to that used for natural gas welding. A flux density covered rod is used .

Atomic Hydrogen Welding

This weld summons consists of maintaining an arc between two tungsten electrodes in an atmosphere of hydrogen gasoline .
The process can be either manual or automatic with procedures and techniques close related to those used in oxyacetylene weld .
Since the hydrogen shield surrounding the base alloy excludes oxygen, smaller amounts of flux are required to combine or remove aluminum oxide. Visibility is increased, there are fewer flux density inclusions, and a very sound metallic element is deposited .

Stud Welding

Aluminum stud weld may be accomplished with conventional arc scantling welding equipment, using either the capacitor discharge or reap arc capacitor discharge techniques .
The ceremonious arch stud welding process may be used to weld aluminum stud 3/16 to 3/4 in. ( 4.7 to 19.0 millimeter ) diameter .
The aluminum stud welding artillery is modified slenderly by the addition of a especial adapter for the control of the high purity shielding gases used during the weld bicycle. An add accessory control for controlling the plunge of the scantling at the completion of the weld bicycle adds materially to the quality of dyer’s rocket and reduces spatter loss .
Reverse polarity is used, with the electrode gunman positive and the workpiece negative. A little cylindrical or cone shaped project on the end of the aluminum stud initiates the discharge and helps establish the longer arc duration required for aluminum weld .


The unshielded capacitor discharge or draw arc capacitor fire stud weld processes are used with aluminum studs 1/16 to 1/4 in. ( 1.6 to 6.4 millimeter ) diameter .
Capacitor discharge welding uses a low voltage electrostatic storage system, in which the dyer’s rocket energy is stored at a low voltage in capacitors with gamey capacitance as a office reservoir. In the capacitor exhaust stud welding procedure, a small tip or project on the end of the scantling is used for arch trigger .
The draw arch capacitor free stud welding serve uses a stud with a point or slenderly round end. It does not require a serrate tip or projection on the end of the dot for arc knowledgeability. In both cases, the dyer’s rocket cycle is exchangeable to the conventional stud welding process. however, use of the projection on the base of the dot provides the most reproducible welding .
The short circuit arch clock of the capacitor release process limits the liquescent thus that shallow penetration of the workpiece results. The minimum aluminum oeuvre thickness considered practical is 0.032 in. ( 0.800 millimeter ) .

Electron Beam Welding

Electron air weld is a fusion joining process in which the workpiece is bombarded with a dense pour of high-speed electrons, and about all of the kinetic energy of the electrons is transformed into heat upon impact .
Electron beam welding normally takes place in an evacuate chamber. The chamber size is the limiting gene on the weldment size. Conventional arc and boast heat melt fiddling more than the coat. further penetration comes entirely by conduction of heat in all directions from this molten airfoil spotlight. The fusion zone widens as it depends .
The electron balance beam is capable of such intense local inflame that it about instantaneously vaporizes a hole through the stallion joint thickness. The walls of this hole are molten, and as the hole is moved along the joint, more metallic on the advancing side of the hole is melted. This flaws around the tidal bore of the fix and solidifies along the rear english of the hole to make the weld .
The intensity of the shine can be diminished to give a partial penetration with the same narrow shape. Electron beam weld is generally applicable to edge, butt joint, fillet, melt-thru lap, and spot welds. Filler alloy is rarely practice except for come on .

Welding Resistance Welding

The aluminum welding resistance weld processes ( spot, wrinkle, and dart weld ) are authoritative in fabricating aluminum alloys. These processes are specially utilitarian in joining the high-strength heat-treatable alloys, which are difficult to join by fusion welding but can be joined by the resistance welding march with much no loss in strength .
The natural oxide coating on aluminum has a preferably senior high school and erratic electric resistance. To obtain descry or seam welds of the highest force and consistency, it is normally necessary to reduce this oxide coating prior to welding .

Welding Spot Welding

Welds of uniformly high strength and good appearance depend upon a systematically low surface resistance between the workplaces. For most applications, some clean operations are necessity before descry or seam weld aluminum .
Surface homework for welding by and large consists of removal of grease, oil, scandal, or recognition markings, and reduction and improvement of consistency of the oxide film on the aluminum coat. The satisfactory operation of spot welds in service depends to a big extent upon the joint design .
blemish welds should always be designed to carry shear loads. however, when tension or combined loadings may be expected, particular tests should be conducted to determine the actual potency of the joint under overhaul cargo .
The lastingness of spot welds in aim tension may vary from 20 to 90 percentage of the shear potency .

Seam Welding

Seam weld of aluminum and its alloy is very exchangeable to spot weld, except that the electrodes are replaced by wheels .
The spots made by a seam welding machine can be overlapped to form a flatulence or liquid tight articulation. By adjusting the time, the wrinkle welding machine can produce uniformly spaced spot welds equal in quality to those produced on a regular touch welding machine, and at a fast rate. This operation is called roll touch or intermittent seam welding .

Aluminum Flash Welding

All aluminum alloys may be joined by the dart welding work. This process is particularly adapted to making butt or miter joints between two parts of exchangeable cross-section. It has been adapted to joining aluminum to copper in the form of bars and tubing. The joints so grow fail outside of the weld area when tension loads are applied .

Aluminum Gas Welding

Gas welding has been done on aluminum using both oxyacetylene and oxyhydrogen flames. In either shell, an absolutely neutral flame is required. Flux is used a well as a filler perch. The action besides is not besides popular because of gloomy heat remark and the want to remove flux .

Electroslag Welding

Electroslag weld is used for joining arrant aluminum but is not successful for welding aluminum alloys. Submerged arc welding has been used in some countries where inert natural gas is not available .

Other Processes

Most of the solid-state welding processes, including friction welding, supersonic welding, and cold weld are used for aluminum. aluminum can besides be joined by soldering and brazing. Brazing can be accomplished by most braze methods. A high silicon alloy filler material is used.

For Additional Reading

Aluminum Gas Welding
aluminum Soldering
More on Tig Welding Aluminum

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