Articles & Podcast Episodes

To weld aluminum, start by cleaning the surfaces and removing oxide. File the edges for a proper fit. Use a pushing welding technique at a 10 to 15-degree angle. Make multiple passes with straight beads. This method improves appearance and minimizes defects. First, clean the aluminum surface thoroughly. Remove dirt, grease, or oxidation using a … Read more

The “stack of dimes” in aluminum welding is a pattern that looks like stacked coins. This effect happens when cooling rates differ and create unique bead shapes. To achieve it, welders must control heat effectively and add the filler rod accurately. This appearance is common in TIG welding techniques, enhancing both clarity and accuracy. Surface … Read more

The Standard Welding Procedure Specification (SWPS) for aluminum outlines key variables for Gas Tungsten Arc Welding (GTAW). It applies to aluminum alloys like 5083, with gauge thicknesses from 10 to 18. Follow AWS standards, such as AWS D1.2, for proper compliance and consult documentation for your specific requirements. By utilizing SWPS, organizations can streamline their … Read more

Spot welding fuses aluminum pieces using heat, creating a strong, seamless join ideal for thin materials. Riveting connects aluminum with mechanical fasteners called rivets, leaving visible seams. Spot welding is faster and provides a cleaner finish, while riveting allows versatility for thicker materials in construction and manufacturing. Spot welding offers a quick and efficient joining … Read more

Spray arc welding is a technique that uses an electric arc to spray molten aluminum from an electrode wire. This molten metal fuses with a base material, typically thick aluminum. For optimum results, this process requires a welding current above 350 A. It is effective for joining large aluminum sections. Second, select the correct parameters. … Read more

Spray transfer MIG welding aluminum uses high travel speeds and wire feed speeds with high amperage and voltage. This technique generates small molten droplets across the arc, maintaining arc stability. It achieves a high metal deposition rate, making it an efficient choice for aluminum welding. Aluminum welding requires specific settings due to aluminum’s unique properties. … Read more

Spray transfer is a metal transfer technique used for welding aluminum. It moves small molten metal droplets from the electrode to the molten pool. These droplets are smaller than the electrode diameter. This approach prevents short-circuiting and produces a high-quality weld with minimal spatter. Beginners will appreciate the increased heat input and stable arc characteristics … Read more

Square wave welding is a TIG welding method for aluminum. It improves cleaning action by breaking up oxidation, resulting in higher weld quality. This technique offers better arc control than sine wave AC. While it’s beneficial, it isn’t necessary for good aluminum welds. Using the right settings and tungsten electrode is also important. Start with … Read more

Spray powder welding is a process that sprays molten metal particles onto surfaces to create coatings or build components. It often uses aluminum-bronze for its wear resistance and thermal conductivity. Techniques like Twin Arc and Flame Spray are common, and this method is valuable in machining and micro-welding applications. The techniques used in spray powder … Read more

The Lincoln Square Wave TIG 355 is a specialized TIG welder for aluminum welding. This machine offers full operator control, especially with AC TIG welding settings. It has a 350 amp capacity to manage heat effectively. Correct settings are crucial for optimal arc generation and successful welding techniques using the tungsten electrode. Set the amperage … Read more