Articles & Podcast Episodes

Forged aluminum wheels can be difficult to weld because of alloy restrictions. Alloys like 2XXX and 7XXX may lose strength during welding. While TIG welding is an option, it risks issues such as porosity. Always consult a wheel manufacturer or expert for repair recommendations before starting any welding work. For effective repairs, it is crucial … Read more

To weld diamond plate aluminum, start by cleaning the surface with acetone and a wire brush. Use a spool gun for MIG welding and select the right aluminum filler wire. Control the heat carefully to ensure strong, durable welds. Practice with beginner-friendly aluminum welding kits to improve your skills and weld quality. Next, choose the … Read more

Pulsed MIG welding improves aluminum welding by controlling heat input. This reduces warping and spatter. It works well on different material thicknesses and uses a push-pull gun for consistent feeding. Recent advancements enhance weld quality and thermal management, making this technique versatile for both thin and thick aluminum materials. For successful pulsed MIG welding, consider … Read more

Aluminum bike frames can be re-welded reliably, but their strength won’t equal steel. Welding can soften the material and affect its alloy temper. Heat treatment is often necessary to restore strength. 7005 frames may benefit from room temperature aging, while 6061 needs post-weld heat treatment by a skilled welder. Next, select the right filler rod. … Read more

Spot welding aluminum sheet joins aluminum pieces using high welding current. This process needs about 30,000 to 40,000 amps due to aluminum’s low electrical resistivity. Clean surfaces and proper electrode types ensure strong bonds. To improve the weld quality, consider using steel as the electrode material for better performance. Next, utilize the right electrode type. … Read more

To MIG weld aluminum, set the voltage between 21-24 volts and wire feed speed to 250-470 IPM. Use DCEP polarity and preheat the aluminum to around 200°F. For better heat control, apply pulse welding. Select appropriate filler metals like 5356 or 4047 to ensure strength in your weld. Using a shielding gas is crucial in … Read more

Sandblasting aluminum before welding cleans the surface but may quickly create an oxide layer. Use suitable blast media and keep pressure low to prevent warping. Avoid sandblasting for critical applications, as it can introduce porosity. Always clean the surface right before welding to achieve the best results. Proper technique is essential during sandblasting. Hold the … Read more

DCEN, or direct current electrode negative, is preferred for welding aluminum because it reduces oxidation. Aluminum’s high sensitivity to oxidation forms aluminum oxide on its surface. This oxide layer makes it hard to start the arc. DCEN effectively creates strong and clean welds by overcoming these arc starting issues. The benefits of TIG welding with … Read more

Aluminum welding rods work effectively. They create a strong bond that exceeds the strength of mild steel. These rods minimize distortion in the aluminum parent material during the welding process. Unlike traditional methods, they do not need flux or extra welding materials, making the welding process simpler and producing a robust weld. User experiences highlight … Read more

To clean cast aluminum before welding, follow these steps: 1. Remove oil and grease with acetone or a mild soap solution. 2. Use a stainless steel wire brush or an alkaline/acid solution to eliminate surface oxides. 3. After cleaning, assemble the joint carefully to ensure a strong weld. Proper cleaning techniques involve scrubbing the surface … Read more