Articles & Podcast Episodes

Laser welding aluminum to steel uses focused heat to join the metals. It partially melts aluminum for better bonding with steel. This method maintains metallurgical integrity and combines the advantages of fusion and brazing. It has applications in industries like automotive and aerospace, providing strong connections through precise technology. Innovations in filler materials also play … Read more

A CC pulse in aluminum welding controls amperage to reduce heat input, which prevents warping. It provides a steady current despite voltage changes. This method improves weld quality by minimizing spatter and enhancing consistency. Pulsed MIG is effective for achieving better weld fusion, making it suitable for delicate materials like galvanized steel. The applications of … Read more

Stress cracking in aluminum welding occurs during cooling due to excessive shrinkage stresses. Key factors include a concave bead profile, slow travel speed, and a restrained joint. Crater cracks, or depressions at the weld’s end, also impact weld integrity. These factors contribute to failures in aluminum welding. Another significant cause is the presence of galvantic … Read more

TIG welding aluminum, known as Gas Tungsten Arc Welding (GTAW), uses a tungsten electrode to bond aluminum sections. This technique needs careful settings, such as AC balance and frequency. It is great for making precise welds on different joint types. Begin your practice with our beginner guide and helpful tutorials! Learning about aluminum welding with … Read more

To weld aluminum with a flame, start by lighting the torch. Adjust it to a “just-off-feather” flame. Preheat the aluminum workpiece to 500-600°F, particularly for thicker sections. Remember, aluminum won’t change color at its welding temperature of 1250°F. Always prioritize safety throughout the welding process. Flame techniques require careful temperature control. Aluminum melts at a … Read more

To weld aluminum with wire feed, use MIG welding techniques. Set correct heat and wire feed speed. A spool gun improves wire feed consistency. Prioritize safety; wear protective gear to shield against UV exposure. Learn about joint configurations for strong welds. Regular practice enhances your skills and leads to better results. Next, consider the type … Read more

TIG welding parameters for aluminum vary by material thickness and position. For 1/8-inch thickness: Horizontal and Vertical at 120 amps, Overhead at 135 amps. For 3/16-inch thickness: Flat at 215 amps, Horizontal and Vertical at 180 amps. Adjust these settings based on your specific welding project needs. For medium thickness, between 1/8 and 1/4 inch, … Read more

TIG welding aluminum at a 90-degree angle requires careful technique. Ensure joints fit well and set the groove angle to at least 90 degrees. Maintain a steady travel speed. Use tack welding to avoid distortion. If needed, incorporate structural supports for stability. Follow these tips to improve joint precision and structural integrity. Choosing the right … Read more

After welding aluminum, anodizing may cause discoloration, particularly with high-silicon fillers like 4043. Using 5356 filler can reduce darkening. It’s important to remove all oxidation before anodizing. While anodizing improves the surface finish, the color of welded areas might differ from the rest. Firstly, ensure thorough cleaning of the welded areas. Contaminants from welding can … Read more

Anodized aluminum has welding challenges. The aluminum oxide layer serves as an electrical insulator, making arc ignition and stability difficult. Moreover, aluminum melts at 1,260°F, but aluminum oxide needs about 3,700°F to melt. These factors impact effective welding techniques on anodized aluminum surfaces. Additionally, selecting the right filler material is crucial. Filler rods compatible with … Read more