Articles & Podcast Episodes

Welding magnesium to aluminum is difficult. The joint often weakens when using aluminum filler metal, risking structural integrity. This is important for costly magnesium castings. For better durability, explore specialized welding techniques or filler metals designed for joining different materials. Preheating is crucial before welding. This process reduces the risk of cracking and improves the … Read more

Porosity in aluminum welding occurs mainly due to hydrogen trapped in the weld pool as it solidifies. Factors like heat, contamination, and gas absorption contribute to this issue. Contaminants can introduce hydrogen. Using proper gas flow and controlling heat can lower the risk of porosity, leading to a cleaner weld. To troubleshoot porosity in aluminum … Read more

OSHA sets requirements for welding aluminum to protect workplace safety. The permissible exposure limit (PEL) for aluminum is 5 mg/m3 for respirable dust and 15 mg/m3 for total dust, averaged over an 8-hour shift. Complying with these limits helps prevent health risks from aluminum fumes. OSHA also sets permissible exposure limits (PELs) for harmful substances. … Read more

Preheating cast aluminum before welding is crucial for improving weld quality. It reduces porosity by removing water vapor and oil. The ideal preheat temperature is between 200 to 300°F. This process slows the cooling rate and helps prevent weld cracking. Mechanical cleaning is also important for achieving optimal weld results. The benefits of preheating cast … Read more

For MIG welding aluminum, the best shielding gas is 100% Argon. This gas prevents oxidation, which is crucial for aluminum. Unlike mixed gases like Argon and CO2 that work well with steel, using pure Argon ensures a cleaner weld. This improves the quality and strength of the joint in aluminum welding. An argon-helium mixture offers … Read more

Scratch start TIG welding aluminum means starting the arc without high-frequency (HF) help. Use the right shielding gas to protect the weld pool. Place the gas cup on the metal, then use the tungsten electrode to start the arc. Practice the correct technique to avoid arc trails and achieve a quality weld. Control heat input … Read more

Robotic TIG welding of aluminum uses advanced technology for precise, high-quality welds. It features a reliable power source and efficient wire feed. This method is ideal for many applications, providing clean, strong welds with minimal heat distortion. Automation enhances production speed and improves overall efficiency. Aluminum is a popular material in industries like automotive and … Read more

Reverse polarity welding aluminum uses Direct Current Electrode Positive (DCEP). This method concentrates heat at the electrode, improving weld quality. It allows for higher penetration and creates a narrow weld profile. Most aluminum welding rods work well with this technique. For best results, use an AC reactor during the process. When using reverse polarity, it … Read more

Resistance spot welding aluminum requires high current due to aluminum’s low electrical resistance. Key factors are selecting appropriate electrodes and adjusting welding parameters. This process effectively joins metal sheets while overcoming electrical conductivity challenges. Using proper techniques results in strong and reliable welds, crucial in automotive manufacturing. Additionally, controlling the weld time and current is … Read more

To achieve the best weld quality in MIG welding aluminum, use the push technique. Pushing the welding gun away from the weld pool enhances the cleaning action, improves shielding gas coverage, and reduces weld bead contamination. This method produces stronger and cleaner welds compared to the pull technique. Both techniques have their advantages and disadvantages. … Read more