Articles & Podcast Episodes

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

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