Articles & Podcast Episodes

To fix broken aluminum without welding, use a propane torch and brazing rods. Heat the aluminum to create a bond through capillary action. For simpler repairs, try adhesive alternatives like epoxy putty. This two-part material forms a durable bond and is easy to use for effective repairs. It is essential to prepare the surface before … Read more

Electron Beam Welding (EBW) is a modern method to join aluminum alloys, such as 6061 and 7075. EBW produces strong welds with minimal distortion. It uses high-velocity electrons to fuse materials, making it ideal for aerospace applications and large structures. This process also reduces imperfections like cavities in the welds. The precise control of the … Read more

Use aluminum welding electrodes for strong joints in arc welding. Brands like HARRIS® and Techniweld provide electrodes for alloy types and pure aluminum. These rods work well with shielding gas to create clean weld pools. They are perfect for applications in castings, tubes, and sheet metal, ensuring high-speed deposition and machinable welds. The benefits of … Read more

Fiber laser welding is a precise method for joining aluminum. It uses a 1064nm wavelength for accurate control of heat. This process allows for high-speed welding with low heat input. It is well-suited for automation. Fiber laser welding also addresses challenges like aluminum’s high reflectivity and the presence of alloying elements. Effective preparation of aluminum … Read more

To ensure quality in cast aluminum repair welding, prepare the weld area by removing defects and cleaning the oxide layer. Preheat the section before welding. Select a suitable weld rod based on its chemistry. After welding, dress the joint to restore its shape. Finally, consider heat treatment to enhance weld strength. Expert options for repair … Read more

The argon flow rate for MIG welding aluminum should be between 25-35 cubic feet per hour (CFH). This flow rate provides effective shielding for the weld. Consider factors such as the thickness of aluminum, the type of joint, and environmental conditions to determine the best flow rate. Pressure settings also play a significant role in … Read more

Anti-spatter solutions for aluminum welding stop splatter from sticking to metal. They improve corrosion resistance and make cleanup easy. Water-based formulas work well. Cost-effective choices include mixing dish soap with water. Non-flammable solutions ensure safety in high-temperature areas. Several essential products assist in the use of anti-spatter for aluminum welding. For instance, anti-spatter sprays act … Read more

Annealing aluminum after welding is a heat-treating process that refreshes work-hardened metal. For 6061-T6, heat it to about 750°F for two hours, followed by controlled cooling. Note that 5052 cannot be heat-treated but can be work-hardened. Following these techniques keeps the aluminum structure intact. The annealing process involves heating the aluminum to a specific temperature. … Read more

TIG welding aluminum requires specific settings. For 1/8” thickness, use 120 amps in horizontal and vertical positions. For overhead, set to 135 amps. For 3/16” thickness, use 215 amps in flat position and 180 amps in horizontal and vertical positions. Adjust these parameters according to welding specifications and heat input requirements. Techniques also matter in … Read more

When TIG welding 1/8 inch (0.125 inch) aluminum, use about 125 amps. This follows the guideline of 1 amp for every thousandth of an inch of thickness. This ensures the right heat input for effective welding. Always make adjustments based on your specific project needs and the properties of the aluminum material. For TIG welding … Read more