Articles & Podcast Episodes

Stress cracking in aluminum boats often happens at weld joints due to small fillet sizes or concave shapes. To repair, stop drill the ends of the cracks and add reinforcing plates. Use silicon filler metal to reduce shrinkage stresses. Addressing these issues helps prevent future cracks. Prevention of stress cracking is crucial. Welders should use … Read more

Stress relief for aluminum after welding involves heating it to 570°F to 770°F for up to three hours. This process reduces residual stresses that can lead to distortion, cracking, and weld defects. For T6-treated 6061 aluminum, perform rough cuts before stress relief to ensure optimal results. Key techniques for stress relief in aluminum include annealing … Read more

The structural welding temperature for aluminum ranges from 577°C to 632°C (1070°F to 1170°F). This range depends on the aluminum type and the welding process used. Knowing the melting point and weldability of the aluminum alloy is important for effective welding results. Optimal techniques for structural welding aluminum include maintaining a consistent heat input and … Read more

Friction stir welding (FSW) is a solid-state process that uses a rotating, non-consumable tool to join aluminum plates. It generates frictional heat to fuse materials without melting. FSW provides high tensile strength, environmental benefits, and economic advantages, making it suitable for various industry applications, especially in automotive. The benefits of stir friction welding include high … Read more

To perform stud welding on aluminum effectively, start with thorough surface preparation. Use the capacitor discharge process for efficient, quick welds. Make sure to calibrate the aluminum CD welder properly. Incorporate ceramic ferrules to enhance the welding process. This method ensures a strong and reliable connection. There are several options in stud welding for aluminum. … Read more

Surface preparation of aluminum for spray welding includes two main steps. First, clean the surface by removing oil, grease, and hydrocarbon contaminants to prevent weld defects like porosity. Second, eliminate oxide layers to avoid lack of fusion. Proper surface preparation is critical for achieving a strong and reliable weld. Next, mechanical abrasion enhances surface texture. … Read more

Submerged Arc Welding (SAW) is a welding method that uses a covered arc for high-quality joins. However, it is not ideal for aluminum due to its low melting point. For aluminum welding, processes like MIG welding and TIG welding work better. SAW is mainly effective for ferrous materials, offering better penetration and weld cleanliness. Comparatively, … Read more

Carbon arc welding is effective for aluminum and other non-ferrous metals. This method reduces oxidation, leading to strong, high-quality welds. Gas carbon arc welding also limits contamination. It suits applications that require precision and durability when joining reactive materials. To succeed in this method, first ensure proper preparation of the aluminum surface. Clean the metal … Read more

The AWS aluminum welding standards include AWS A2.4 for welding symbols and AWS D1.2 for structural welding. These standards outline requirements for aluminum structural alloys but exclude pressure vessels. For TIG welding certification of 6061-T6 aluminum, following the Welding Procedure Specification (WPS) and Welding Technique Specification (WTS) is crucial. Specifications detail the appropriate filler materials … Read more

Brazing joins dissimilar metals using lower temperatures, making it suitable for applications needing low thermal distortion. Welding joins similar base metals with high heat, creating strong joints. Each process serves different purposes across industries, depending on the specific requirements for strength and heat sensitivity. In terms of strength comparison, brazed joints often outperform welded joints … Read more