Articles & Podcast Episodes

Hot cracking in 3003 aluminum welding is the development of cracks during solidification. This issue arises from the alloy’s properties and is worsened by the welding process. Factors like high-temperature conditions and the heat-affected zones play a role. Using suitable filler materials and techniques helps reduce the chance of hot cracking. Controlling the workpiece temperature … Read more

Heat is vital in aluminum welding. Excess heat can lead to hot cracking, porosity, and weaken the heat-affected zone (HAZ). Pre-heating to about 250°F helps. Aluminum cools quickly, so focused heat is necessary to avoid warping and burn-through. Effective techniques and careful heat management ensure successful welds. Additionally, preheating the aluminum can help reduce thermal … Read more

Ron Covell shares expert tips for aluminum welding. Use AC current for welding and DC for tungsten. Adjust power settings to 1 ampere per 11,000 inches of material. For MIG welding, consider using a spool gun. Watch his video resources for detailed techniques and best practices in metalworking. Another critical tip is selecting the right … Read more

Hot cracking in aluminum welding happens during solidification. Cracks appear because the metal loses ductility as it cools. To prevent hot cracking, welders can preheat the joint and select the right filler metal. Knowing these factors is key for the welding community to achieve successful aluminum welds. Second, preheating the aluminum base material can enhance … Read more

To begin spool welding aluminum, set up your MIG welder with 100% argon gas at a flow rate of 20 cubic feet per hour. Choose 4043 wire for general work. Adjust your machine for the aluminum thickness you are using. Start welding 1/4” away from the base metal. Follow these techniques for better results. To … Read more

To clean cast aluminum for welding, start with an organic solvent like acetone to eliminate oil and grease. Then, use a stainless steel wire brush or an alkaline solution to remove surface oxides. Ensure the surfaces are dry before assembling the joints. This method ensures clarity and thorough cleaning, making it suitable for welding. Next, … Read more

To clean aluminum for welding, follow these steps: 1. Use acetone or a mild detergent to remove oil, grease, and moisture. 2. Use a stainless steel wire brush or an alkaline solution to remove surface oxides. 3. Assemble the joint quickly to achieve the best results. For stubborn stains, use a mixture of water and … Read more

To perform DC negative (DCEN) TIG welding on aluminum, set the welder to DCEN. Connect the torch to the negative terminal and the work clamp to the positive terminal. Use 100% argon as the shielding gas. DCEN improves penetration and optimizes heat input, making it crucial for effective aluminum welding. Maintain a proper travel speed. … Read more

To determine which aluminum welding wire to use, consider your project requirements. Select ER4043 for good aesthetics and ease of control, perfect for cosmetic finishes. Choose ER5356 when tensile strength and corrosion resistance are crucial, making it a better fit for structural applications. Additionally, the wire’s diameter affects the heat and penetration during welding. Thinner … Read more

To ball tungsten for aluminum TIG welding, first sharpen the tungsten point. Set your welder to DC polarity. Strike an arc on brass or copper while gradually increasing the amperage. Keep the torch about 1/8 inch from the surface. This method helps the tungsten form a ball for better welding performance. Next, use a TIG … Read more