Articles & Podcast Episodes

To weld aluminum with a spool gun, use the push technique instead of pulling. Start with a high wire feed speed and lower it as needed. Listen for the welding sound; avoid a “bacon frying” noise, as it means the wire feed is too high. Always snip the wire between welds to ensure better performance. … Read more

To weld aluminum with a spool gun, use a MIG welder with 100% argon gas at 20 cubic feet per hour. Start with a high wire feed speed and adjust down as needed. Maintain a push angle for better shielding. Consider a Teflon liner for smooth wire feeding. Pay attention to contact tips for optimal … Read more

Laser absorptivity in aluminum welding depends on alloy composition and laser settings. At a laser wavelength of 1060 nm, aluminum achieves an absorption value of 79.5%. More magnesium content boosts weld penetration and minimizes spatter. Adjusting laser power density improves energy absorption for spatter-free welds and better overall welding structure. However, variations in laser absorptivity … Read more

Gas Tungsten Arc Welding (GTAW), or Tungsten Inert Gas (TIG) welding, is the main method for welding aluminum alloys. It offers precise control and avoids mechanical wire feeding, which minimizes feedability issues. GTAW is excellent for thin materials and produces strong, high-quality welds suitable for various aluminum welding applications. Best practices in welding aluminum alloys … Read more

MIG welding aluminum is simple for beginners. First, set up your MIG welder properly. Clean the aluminum to improve adhesion. Choose the right filler wire and adjust your settings. Be aware of aluminum’s challenges. For better results, try a spool gun or push/pull MIG units. Practice will lead to success in the welding process. Next, … Read more

Welding aluminum can be hazardous. Heating aluminum releases aluminum oxide and ozone. Aluminum oxide can irritate the lungs, and ozone is harmful to health. Without protective gear, welders may develop respiratory diseases like aluminosis. Implementing proper safety measures is crucial to minimize these health risks. Additionally, prolonged exposure to these toxic fumes may result in … Read more

Welding aluminum can be challenging due to its low melting point. This can cause warping, cracking, or breaking. To avoid these problems, use the Gas Metal Arc Welding (GMAW) process with pulsation capability. By applying proper techniques, aluminum welders can achieve stronger and more reliable welds. Porosity is also a common concern in aluminum welding. … Read more

Burn-through in aluminum welding happens when too much heat melts the metal, creating holes. This often results from poor welding technique or incorrect amperage settings. Contamination can also cause issues. Properly cleaning the aluminum and adjusting the heat with appropriate speed can prevent burn-through, ensuring a strong weld quality. Preventing burn through in aluminum welding … Read more

Friction stir welding (FSW) of AA6061-T6 aluminum alloy improves mechanical properties in a butt joint configuration. It produces strong, high-quality welds with minimal cost and waste. Optimal conditions involve a rotating speed of 1800 r/min. Understanding microstructural evolution is essential for enhancing joint quality. The mechanical properties of welded 6061-T6 sheets under Friction Stir Welding … Read more

Friction stir welding (FSW) for aluminum alloys requires important parameters: welding speed, rotational speed, plunge depth, and spindle torque. Additionally, shoulder design, base material, pin profile, and tool type are vital. These factors greatly affect weld quality and joint strength. Higher rotational speeds generally increase heat input, leading to improved mechanical properties. However, excessively high … Read more