Articles & Podcast Episodes

Phosphoric acid etches aluminum effectively after welding. It creates a rough surface texture that improves adhesion and increases corrosion resistance. This solution works well for aluminum and other metals, making it a valuable option in metal preparation for various applications. Common etchant solutions for aluminum include a mixture of sodium hydroxide and water. This solution … Read more

To weld aluminum effectively with TIG, keep these tips in mind: 1. Maintain a proper hand position for better control. 2. Keep a consistent distance for even heat. 3. Control temperature to avoid warping. 4. Know aluminum’s conductivity. 5. Clean the workpiece to improve adhesion. These techniques benefit beginners. Choose the right welding method. Common … Read more

To TIG weld aluminum, use high purity argon as the shielding gas. Ensure the argon is at least 99.998% pure and has a dew point of 10 ppm or lower. This inert gas protects the weld area from contamination. Maintain proper flow rates to achieve the best results during the welding process. For applications requiring … Read more

To weld aluminum with a spool gun, start with a high wire feed speed and adjust as needed. Use 100% argon gas and set the flow rate to 20 cubic feet per hour. Angle the gun for better adhesion. You may need 3-4 contact tips per pound of wire. Use quality welding tips for optimal … Read more

Gas Tungsten Arc Welding (GTAW), known as TIG, is the best choice for aluminum welding. It provides high precision and superior heat control. Unlike methods that need mechanical wire feeding, TIG does not face feedability issues. This technique creates clean, strong welds, making it ideal for detailed aluminum projects. Each technique presents unique tips and … Read more

The white powder formed when welding aluminum is called “frosting.” This results from the arc’s cleaning action, which removes impurities. The frosting indicates aluminum oxide on the surface. Adjusting the balance during arc welding can reduce frosting. While it affects the surface finish, it does not compromise the weld quality. The risks associated with this … Read more

Aluminum welding made great strides after World War II. In 1948, the Battelle Memorial Institute developed MIG welding, which they patented for aluminum the next year. Inert gas welding methods also improved during the 1940s, enhancing aluminum’s strength as a structural material for many applications. In 1925, the advent of the gas tungsten arc welding … Read more

Meredith invented aluminum welding by patenting the Heliarc welding process in 1941. This method effectively welded aluminum, magnesium, and stainless steel. Linde Air Products later licensed this technique and created a water-cooled torch to improve efficiency in the welding process. Later, the development of gas tungsten arc welding (GTAW), also known as TIG welding, in … Read more

Silicon Carbide is ideal for aluminum welding prep. It removes oxidation and prepares surfaces effectively. Aluminum oxide at 80 grit works well too. For finishing touches, use Scotch Brite pads. These choices help ensure clean and strong Class A welds in critical applications. Use ARO pneumatic angle die grinders for best results. Moving to a … Read more

Aluminum welding gained importance with the invention of Metal Inert Gas (MIG) welding in 1948 by the Battelle Memorial Institute. The patent for aluminum welding was granted in 1949. MIG welding transformed aluminum welding by providing a more efficient and effective way to join aluminum in various applications. As World War II approached, the demand … Read more