Welding Wisdom for Professionals and Beginners Alike.

Welding aluminum can be difficult because it has high thermal conductivity. This property causes rapid heat dissipation and possible distortion. Moreover, aluminum can absorb hydrogen, leading to defects. By understanding…

To prepare tungsten for aluminum welding, choose a 1/8 inch tungsten electrode. Shape the tip to a 30-degree angle for better heat distribution. Use low amperage to gradually ball the…

Vaporized aluminum welding creates harmful fumes. These fumes can cause respiratory issues such as cough and lung irritation, along with metal fume fever. Long-term exposure may lead to serious health…

For MIG welding aluminum, use 100% argon as the shielding gas. Set the flow rate between 15 and 30 cubic feet per hour (CFH) for the best results. Avoid argon-helium…

Hot cracking in 3003 aluminum welding is the development of cracks during solidification. This issue arises from the alloy’s properties and is worsened by the welding process. Factors like high-temperature…

Heat is vital in aluminum welding. Excess heat can lead to hot cracking, porosity, and weaken the heat-affected zone (HAZ). Pre-heating to about 250°F helps. Aluminum cools quickly, so focused…

Hot cracking in aluminum welding happens during solidification. Cracks appear because the metal loses ductility as it cools. To prevent hot cracking, welders can preheat the joint and select the…

Ron Covell shares expert tips for aluminum welding. Use AC current for welding and DC for tungsten. Adjust power settings to 1 ampere per 11,000 inches of material. For MIG…

To clean cast aluminum for welding, start with an organic solvent like acetone to eliminate oil and grease. Then, use a stainless steel wire brush or an alkaline solution to…