Articles & Podcast Episodes

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

Preheating 1/4 aluminum before welding is usually unnecessary. If you decide to preheat, limit the temperature to 200 degrees Fahrenheit. This step reduces condensation and moisture, which can harm the weld quality. Always ensure the surface is clean and dry for the best results in aluminum welding. When preheating, you can use various techniques, including … Read more

Ron Fournier’s DVD, “How To Gas-Weld Aluminum,” teaches the basics of gas welding aluminum. It covers needed equipment, methods, and benefits like tack-welding and joint preparation. You will learn to create butt-welds and fusion-type welds. Workshops offer hands-on experience for better craftsmanship in metal fabricating. Fournier’s expert tips highlight the value of practice and experimentation. … Read more

Rotary Friction Welding (RFW) is a solid-state joining process for aluminum and other metals. In this method, one part rotates quickly while pressing against a stationary piece. RFW creates strong, durable bonds without melting the materials. It effectively joins aluminum with titanium and other alloy systems, including copper alloys. Applications of rotary friction welding aluminum … Read more

A Safety Data Sheet (SDS) for aluminum welding details hazards like welding fumes, electric shock, and fire risks. It meets OSHA standards. Users must be aware of inhalation risks, like aluminum fumes, and overexposure to toxic substances. Protective equipment is crucial for safe welding practices. Protective equipment is vital when welding aluminum. Personal protective equipment … Read more

When welding aluminum, safety precautions are essential. Use a fume extractor to clear harmful fumes. Wear a respirator, welding mask, gloves, and protective clothing. Ensure proper ventilation to reduce health risks. Follow OSHA standards and always prioritize personal protective equipment (PPE) for your safety. To manage hazards, ensure proper ventilation in your workspace. Good airflow … Read more

This Welding Procedure Specification (WPS) outlines gas tungsten arc welding (GTAW) for aluminum alloys, such as 6061-T6, using filler material AWS A5.10 ER5356. It details welding parameters, joint types, and requirements for AWS bend tests, ensuring compliance with AWS D1.2 standards and General Welding Standards for effective results. Essential specifications cover the welding process, such … Read more