Articles & Podcast Episodes

Pulsed MIG welding improves aluminum joints by controlling the arc and deposition rates. Adaptive aluminum welding automatically adjusts wire feed speed and arc length for consistency. In contrast, non-adaptive welding needs manual settings. Adaptive methods reduce porosity and enhance root-fusion, resulting in stronger welds. In contrast, adaptive aluminum welding adjusts parameters in real-time. It responds … Read more

Non-controlled atmosphere aluminum welding uses TIG (Tungsten Inert Gas) and MIG (Metal Inert Gas) methods. These techniques rely on argon as a shielding gas to create strong welds. Both welding processes provide high efficiency and are practical for joining aluminum parts in different environments. On the other hand, MIG welding provides speed and efficiency. It … Read more

The Miller Syncrowave 350 LX needs specific settings for welding aluminum. Use DCEN, set post flow to your liking, and adjust maximum amps to 70-80. For thicker aluminum, set pulse per second (pps) to 2, increasing to 4 or 6 for thinner materials. Tailor high frequency settings based on your setup, and account for joint … Read more

To excel in overhead aluminum welding, use pure argon gas and adjust the flow rate for arc stability. A longer stickout is needed compared to steel. Snip the wire at each start and stop to ensure clarity in your welds. Always push the puddle to prevent contamination and achieve a smooth finish. Additionally, adjust your … Read more

Minimum charges for welding aluminum usually range from $1.25 to $4.00 per inch. Factors affecting this cost include the type of aluminum, project complexity, and thickness. Prices may also vary by location. For an accurate estimate, contact local welding services to discuss your specific requirements. The type of weld you require can impact the price … Read more

The minimum thickness for welding aluminum in industrial applications is typically 1/8 inch (3.2 mm). For specific projects, it can reach 3/8 inch (9.5 mm) or 1/2 inch (12.7 mm). The choice of gas, filler metal, and technique depends on the thickness and the goals of the welding project. Proper preparation is crucial when welding … Read more

To set up your Miller welding machine for 1/8 inch (0.125”) aluminum, start with an amperage of 125 amps. This is based on the formula of one amp per 0.001 inch of material thickness. Adjust the amp setting and welding process according to your speed and technique to achieve the best results. For MIG welding, … Read more

To weld aluminum overhead with MIG, set a high heat and adjust the wire speed. Keep a short stickout for better control. Use spray transfer to minimize soot. Increase wire speed by 10% when welding. Follow these tips for smoother welds. Focus on good techniques for strong results. Preparation is essential. Clean the aluminum thoroughly … Read more

TIG welding aluminum overhead needs careful technique. Control heat to prevent the weld puddle from dropping. Keep the weld area clean and use a sharp electrode. Adjust the electrode angle for better control. With the right setup and technique, overhead welding can be as effective as flat or horizontal positions. Remember to follow safety tips … Read more

Oxy-acetylene welding of aluminum (OAW) uses a neutral flame to melt aluminum. It requires flux to prevent oxidation during the welding process. Welders use a filler rod, typically pure aluminum or 5% silicon. Although not the top choice today, OAW played a key role during World War II for joining aluminum parts. Next, prepare the … Read more