Articles & Podcast Episodes

To clean aluminum for welding, follow these steps: 1. Remove oil, grease, and moisture with an organic solvent like acetone or strong soap. 2. Use a stainless steel wire brush or an alkaline solution to remove surface oxides. 3. Ensure the joint assembly is secure for the best results. Next, use a chemical cleaner specific … Read more

MIG welding is best for thicker aluminum and larger projects. It is fast and efficient. On the other hand, TIG welding is suited for thinner aluminum. It offers precision and a high-quality finish. Knowing the strengths of each method helps you choose the right one based on your project needs. The applications of Mig welding … Read more

For AC TIG welding of aluminum, connect the TIG torch to the positive (+) terminal and the earth lead to the negative (-) terminal. This setup allows for optimal heat distribution. Some welding machines can use a “torch negative” configuration, so always verify your equipment’s specifications before starting. In addition to polarity, several essential tips … Read more

Welding aluminum is harder than welding steel. Its high thermal conductivity causes quick heat loss. This trait makes meticulous surface preparation crucial to prevent cracking. Despite the challenges, skill development through practice and knowledge of techniques, like MIG welding, can help you master aluminum welding. To start, choose the right welding technique. Common methods for … Read more

Excessive soot in aluminum welding can indicate problems with the welding technique or setup. While black smut doesn’t always mean a bad weld, it may impact weld quality if ignored. Proper welding preparation and material choice are essential for achieving cleaner and stronger aluminum welds. To eliminate soot and its negative effects, several methods should … Read more

When welding aluminum, use alternating current (AC). Aluminum is sensitive to oxidation, which creates a layer of aluminum oxide. This layer makes it hard to start the arc. AC helps remove this oxide layer, ensuring a strong connection and a stable arc. In contrast, direct current (DC) is not as effective for aluminum stick welding. … Read more

The best tungsten for aluminum TIG welding is usually 2% lanthanated (blue tip) or 100% tungsten (green tip). Lanthanated tungsten allows for versatile current settings and reduces balling. For 1/8” aluminum, set your welding machine to AC, use 100-130 amps, and adjust the AC balance to around 65% for optimal results. Best practices include cleaning … Read more

Preheat 6061-T6 aluminum to 150-200°C before welding. Use filler metals like 4043 or 5356 to avoid cracking. Remember, welding can lower tensile strength. To reduce porosity, apply proper welding techniques. Understanding these factors improves the quality and integrity of your welds. Filler metal selection is crucial when welding 6061 T6 aluminum. Common filler materials include … Read more

The best tungsten for welding aluminum is usually 2% Lanthanated tungsten (blue tip) or Pure tungsten (green tip). Ceriated tungsten is favored for easy arc starting. Zirconiated tungsten is effective for aluminum and magnesium alloys. Choose reliable brands like Blue Demon, Weldcraft, or CK for high-quality electrodes. When selecting tungsten sizes for aluminum welding, the … Read more

Oxy-fuel welding aluminum uses acetylene and oxygen to join aluminum parts. This process needs proper flux to stop oxidation in the weld puddle. Surface preparation is crucial for quality. A neutral flame keeps temperatures consistent. Suitable filler rods, such as aluminum alloys, improve joint strength and integrity. Safety must always be a priority. Preparation is … Read more