Articles & Podcast Episodes

Hydrogen air welding aluminum creates welds by using hydrogen gas. In molten aluminum, hydrogen has high solubility. As the aluminum cools and solidifies, the solubility decreases. This change causes hydrogen to form gas pores trapped in the weld bead. These defects can weaken the weld, so careful control is crucial during the process. When troubleshooting … Read more

Exposure to aluminum welding fumes poses serious health risks. Acute symptoms include eye, nose, throat, and lung irritation. Chronic exposure can lead to serious conditions like lung disease and nervous system damage. It is important to use protective equipment and ensure proper ventilation during aluminum welding. The toxicity of aluminum fumes also raises concerns about … Read more

The I-CAR aluminum GMA (MIG) welding test measures technicians’ skills in aluminum welding for collision repair. This test is a key part of the welding training program. It includes a welding capability assessment. Technicians spend 40 minutes on equipment familiarization and about three hours completing the test. One effective tip is to practice on various … Read more

Aluminum GMA (MIG) Welding Training and Certification by I-CAR offers hands-on practice. Participants learn MIG welding techniques and welding processes. The training covers industry standards and certification details. Certification lasts three years. Enroll now to enhance your skills and meet aluminum repair requirements. Participants learn about aluminum’s unique properties and how they affect the welding … Read more

Preheating cast aluminum for welding enhances results. The ideal preheat temperature is usually between 212°F and 572°F (100°C to 300°C). For aluminum alloys with copper content, aim for the higher end of this range. Proper preheating helps minimize defects during the welding process. Effective preheating techniques include using a propane torch, an infrared heater, or … Read more

Aluminum resistance spot welding uses high power due to aluminum’s good thermal and electrical conductivity. The welding current is 2–3 times higher than for steel. However, the welding time for aluminum is only one-third of that for steel. This efficiency makes it suitable for aluminum and its alloys using welding guns. The lightweight nature of … Read more

Hybrid laser arc welding (HLAW) combines laser welding and gas metal arc welding. HLAW creates strong welds in aluminum and magnesium alloys. It offers deep penetration and a narrow heat-affected zone. This efficient process is ideal for industrial applications like shipbuilding and high-speed welding. One primary advantage of hybrid laser arc welding aluminum is speed. … Read more

To weld aluminum with MIG welding, clean the metal first. Use a push-pull or spool gun for better wire feeding. Select a thicker wire diameter for stiffness and adjust to a slower welding speed. Trim the wire end to prevent feeding problems. Practice your technique for the best results. Preparation is crucial in mastering how … Read more

To weld aluminum with stick welding, use a DC stick welder set to DCEP polarity. You will see more spatter and a sticky weld puddle. This method is different from steel welding and does not work well for thin stock. For best results, choose thicker aluminum materials to ensure a strong weld. When adjusting parameters, … Read more

To harden aluminum after welding, use solution heat treatment. Heat the aluminum to 970°F for a time based on its thickness, then quench it to cool quickly. For 6063 aluminum in T6 temper, follow with aging to regain strength. If needed, anneal the aluminum to reduce hardness and restore its properties. Hardened aluminum loses strength … Read more