Articles & Podcast Episodes

To spot weld aluminum in a DIY project, place steel shims on both sides of the aluminum sheets. Use shims that are 0.020 inches thick. The shims increase electrical resistance and concentrate heat in a small area. This creates a hot spot necessary for effective welding, while keeping the shims from melting. Next, prepare the … Read more

Spot welding aluminum is an industrial process that joins two aluminum surfaces using high electrical current. The process requires 30,000–40,000 amps and effective grounding. Suitable electrodes create a strong weld. Thermal conductivity and resistivity of aluminum impact welding parameters, while clean surfaces reduce weld defects and improve weld strength. When working with aluminum alloys, tips … Read more

Spot welding aluminum sheets is challenging because aluminum has low resistivity. It needs 30,000 to 40,000 amps and precise welding parameters. Surface preparation is essential; remove the oxide skin for better contact. Choose thin steel sheets as electrodes. Paying attention to current and amperage can improve the welding process and results. To achieve strong welds, … Read more

Resistance spot welding aluminum involves key criteria. Use 2024-T3 aluminum lap joints with a thickness under .065”. Aim for a spot weld diameter of .125”. Achieve quality Class A welds by ensuring proper equipment, techniques, and process settings. Store aluminum correctly to optimize results in automotive body structures. To achieve optimal results, weld parameters must … Read more

To weld aluminum effectively, use stick welding with alternating current (AC) for cleaning. Direct current (DCEP) improves penetration. Both tungsten inert gas (TIG) and metal inert gas (MIG) methods are also effective. Proper technique and setup are crucial for achieving the best results. When choosing electrodes, opt for those specific to aluminum. The E4043 and … Read more

To spot weld aluminum, keep the thickness under 0.063 inches. Aluminum needs higher electrical current and shorter weld times than steel. Use domed electrodes for better consistency. Adjust the amperage between 120-300 amps depending on the thickness to ensure a strong weld. Despite its advantages, spot welding aluminum has limitations. Aluminum’s high thermal conductivity can … Read more

Refill Friction Stir Spot Welding (RFSSW) is an innovative method for joining aluminum sheets. It delivers high joint strength, surpassing traditional techniques like riveting and resistance spot welding. RFSSW eliminates the need for rivets, resulting in a cleaner join that enhances durability and overall performance. Additionally, spot friction welding is energy efficient. It requires less … Read more

Friction welding of aluminum to steel is a solid-state process. It joins these metals without melting. This method uses friction to create heat, producing strong joints. A key technique, hybrid resistance spot welding, handles high tensile loads. It is useful in applications like automotive manufacturing, reducing the need for rivets. Spot friction welding is beneficial … Read more

2024 aluminum has low weldability in spot welding due to its copper content, which can reduce weld quality. While it is possible to spot weld this alloy, techniques like friction stir welding may provide stronger joints. Additionally, 2024 aluminum may be susceptible to stress corrosion cracking post-welding, affecting its durability. Challenges in spot welding this … Read more

To weld aluminum angles with a spool gun, use a push angle of 15-20 degrees. Employ 100% argon gas for shielding. Use 4043 or 5356 filler wire for best results. Keep the arc length at 3/8 to 1/2 inch. Focus on your technique and settings to enhance weld quality and appearance. During the welding process, … Read more