Aluminum Welding

Helium improves aluminum welding by increasing heat input and joint penetration. It works well with Direct Current Electrode Negative (DCEN). When used with Alternating Current (AC), it needs higher voltage levels, which can affect welding arc stability. This higher heat makes helium ideal for welding thick aluminum joints. When using helium in TIG welding, welders … Read more

1100 aluminum is ideal for welding soft metals with similar compositions. It has high weathering and chemical resistance. This alloy is an excellent filler alloy because of its great welding characteristics. Its softness and versatility make it suitable for various welding applications, especially with base metals. Practical applications for 1100 Aluminum include food processing equipment, … Read more

Burnback in aluminum welding occurs during GMAW. It happens when the arc moves up the wire and sticks to the contact tip. Common causes include poor grounding, wrong tip or wire size, slow wire feed speed, and low-quality filler or tip materials. Making the right adjustments can prevent burnback and improve welding quality. To solve … Read more

Holes in aluminum welds occur due to contamination in the weld pool. Common sources of contamination include hydrocarbon paint and oil. During TIG welding, these substances can enter aluminum pores, causing defects. Cleaning surfaces thoroughly before welding can help prevent this problem. The main causes of holes in welding aluminum include inadequate cleaning of the … Read more

Porosity in aluminum welding arises from hydrogen during the welding process. Molten aluminum can absorb hydrogen, and as it cools and solidifies, trapped hydrogen creates gas pockets. These gas pockets cause porosity, negatively impacting the weld’s quality and strength. Understanding this process is essential for successful aluminum welding. Common issues related to porosity in aluminum … Read more

Porosity in aluminum welding occurs mainly due to hydrogen gas becoming trapped in the molten weld pool. Key causes include contamination from hydrocarbons, excessive welding heat, turbulence during welding, and incorrect shielding gas flow. Addressing these issues can help reduce the risk of porosity. To troubleshoot porosity in aluminum welding, first, inspect the cleanliness of … Read more

Dirty surfaces like dust, oil, or grease can cause spatter when MIG welding aluminum. Improper gas settings and high current levels may also increase spatter. Using the wrong electrode or larger wire diameters at low voltages can worsen the issue. Always clean surfaces before welding to reduce spatter. To reduce spatter during MIG welding aluminum, … Read more

Alternating current (AC) is the best choice for aluminum welding. Aluminum tends to oxidize, forming a layer of aluminum oxide that makes starting the arc difficult. AC helps remove this oxide layer. As a result, it improves arc stability and leads to higher-quality welds. In contrast, MIG welding settings require a different approach. A wire … Read more

The color of tungsten for aluminum welding is usually green, which signifies pure tungsten. Welders may also use 2% thoriated tungsten (red) or lanthanated tungsten. Proper preparation is important; electrodes should be ground to a point and have a flat spot on the end for the best performance. Green tungsten electrodes are made from 2% … Read more

Use a DC stick welder for aluminum welding, as AC is not suitable. Apply DCEP polarity, which also works for steel. This method may produce more spatter and a difficult weld puddle. Stick welding is not ideal for thin aluminum due to these challenges. Consider your welding experience when choosing this method for your project. … Read more