Articles & Podcast Episodes

Aluminum grades suitable for welding include 1XXX alloys, known for high conductivity. 4XXX and 5XXX alloys are common filler metals. 6XXX alloys, like 6061, provide strength and corrosion resistance. The 7000 series alloys are harder to weld. Using proper techniques, especially TIG welding, improves the weld’s quality and strength. Cast aluminum alloys, like 319 and … Read more

To find the weld size for aluminum groove welding, check the base metal thickness. For thin-wall tubes, make the weld width three times the material thickness. For materials over 3/16”, bevel the edges instead of using a square groove. For instance, a 3/8” wall requires a weld width of 1-1/8”. Choosing the right aluminum groove … Read more

GMAW welding of aluminum needs specific techniques and materials. Use contact tips with a bore diameter 10-15% larger than the wire diameter. Common filler metals are Alloy 4043 and Alloy 4943. Ensure proper drive rolls for the aluminum wire. Maintain the right interpass temperature for arc stability and always prioritize safety during the process. Set … Read more

This video shows step-by-step instructions for repairing cracks in an aluminum intake manifold. It uses Super Alloy 5 and an oxy-acetylene torch. Key techniques include cleaning, preheating, and drilling holes to prevent crack spread. This guide is perfect for DIY repair enthusiasts and includes essential welding tips for success. During the video, we highlight key … Read more

Aluminum iso phase welding is a method for joining aluminum in isolated phase bus systems. These systems transport large electrical currents in electrical substations and power generating plants. This welding technique helps ensure safety and efficiency by preventing circulating currents from impacting generators and transformers. This welding method minimizes resistance at connection points. It plays … Read more

Smut in aluminum welding is a black residue found on welds. It forms when the boiling points of aluminum and magnesium are low compared to the heat from arc welding. This causes the filler metal to evaporate. Using proper welding techniques can reduce smut formation, leading to cleaner and stronger welds. To reduce contamination in … Read more

To bond aluminum to aluminum without welding, use aluminum epoxy glue or watertight epoxy. Clean and dry the surfaces for better bonding. Wear a mask and gloves outdoors to avoid fumes. Follow the instructions for curing time to ensure a strong and secure bond. Use the right tools for adhesion if needed. Another viable technique … Read more

Fiber laser welding joins aluminum to steel efficiently. This method offers advantages like fast, clean welds and strong seams. The precise control of the melt pool reduces spatter. Hybrid resistance spot-laser welding improves compatibility. These features make fiber laser welding ideal for modern manufacturing applications. The process begins with surface preparation. Clean surfaces ensure better … Read more

Aluminum to steel spot welding uses methods like ultrasonic welding and hybrid resistance spot-laser welding. These techniques work better because aluminum has low resistivity. Use thin steel sheets as electrodes for effective welding. Proper surface preparation and correct welding current and voltage are essential for a successful weld. Challenges in aluminum to steel spot welding … Read more

To weld aluminum trailer frames, follow these best practices: Identify your alloy type and select the right filler wire. Store the filler wire correctly. Preheat the materials to reduce cracking. Use proper welding techniques to ensure weld strength and prevent galvanic corrosion. Hire a qualified welder for the best results. Next, choose the right welding … Read more