Aluminum Welding

Welding aluminum using MIG and TIG processes produces ozone. This byproduct forms when ultraviolet radiation from the welding arc reacts with oxygen in the air. Additionally, using silicon filler in aluminum also increases the amount of ozone generated during welding. Health risks associated with welding aluminum include lung irritation, metal fume fever, and potential neurological … Read more

Argon is the main shielding gas for aluminum welding. It provides a cleaning action and good penetration. For 5XXX-series alloys, using a mixture of argon and helium (up to 75% helium) helps reduce magnesium oxide formation. This improves weld quality and prevents oxide issues during the welding process. First, clean the aluminum thoroughly. Use a … Read more

For TIG welding aluminum, choose lens shades based on the amperage. Use shade 8-10 for up to 50 amps, shade 10 for 50 to 100 amps, and shade 12 for 100 to 200 amps. The correct lens shade protects your eyes from the bright arc during the welding process. Select the appropriate shade for safety … Read more

High-frequency (HF) voltage helps welding aluminum by delivering a high-voltage, low-current signal (5 to 10 MHz). This signal penetrates the aluminum oxide surface, allowing the welding arc to start. It also stabilizes the arc when using alternating current (AC) power supplies, ensuring a steady and effective welding process. Aluminum is prone to oxidation. The high-frequency … Read more

For welding aluminum, the ideal frequency ranges from 120 to 200 Hz. This frequency improves arc control and travel speeds. Frequencies between 80 and 120 Hz can also be comfortable, providing better control. Always adjust the frequency based on your specific welding technique and the thickness of the aluminum for the best results. The frequency … Read more

Certain aluminum types need welding. Pure aluminum (1050) and alloys from the 5000 and 6000 series can be welded. TIG welding works well, using appropriate electrodes and filler materials like 4043. Be aware of toxic fumes when welding. Effective heat management can help address common welding challenges. Several welding techniques are suitable for aluminum welding. … Read more

The national average pay for aluminum TIG welding is about $47,972 a year or $23 an hour. Top earners make around $59,000 annually. The 75th percentile salary is $53,000, while the 25th percentile salary is $41,000. These figures vary based on experience and location. Geographic location significantly impacts earning potential. States with high demand for … Read more

Argon is the main inert gas used for TIG welding aluminum. It effectively shields the weld area, preventing oxidation. For thicker materials, welders often mix Argon with Helium to enhance heat and penetration. This versatility makes Argon the top choice for professionals in various welding techniques. Using a mix of argon and helium can optimize … Read more

Anti-Borax No. 8 Aluminum Welding Flux is a great option for gas welding aluminum. This flux dissolves aluminum oxide, which helps form strong, clean joints. It works well with aluminum in sheet, extruded, or cast form. Its design effectively meets various aluminum welding requirements. Using the best flux for gas welding aluminum can also prevent … Read more

To find the right amperage for welding aluminum with Gas Tungsten Arc Welding (GTAW), use this rule of thumb: use 1 amp for every 0.001 inch of material thickness. For example, if the aluminum is 1/8 inch (0.125 inch) thick, you need about 125 amps of current for optimal results. Techniques also influence the success … Read more