Welding Wisdom for Professionals and Beginners Alike.

To weld 16 gauge aluminum, use a TIG welder, such as the Hobart EX. Remove oxide with a stainless steel brush. Choose the right electrode type, like 2% lanthanated 1/16”….

2000 series aluminum includes high-strength aerospace alloys mixed with copper. These alloys have heat sensitivity, making welding challenging. Friction welding and certain arc processes can enable joining. Resistance spot welding…

Aluminum 6061 and 5052 are weldable alloys. Use 5356 filler for strength or 4043 for crack resistance. Welding 6061-T6 may weaken the alloy from heat. Avoid magnesium silicide, which is…

You can safely weld a small crack in an aluminum rim if it is 1.5 inches or smaller. The crack should be a repairable crack located on the middle or…

Exposure to aluminum welding fumes can irritate the eyes, nose, throat, and lungs. Long-term exposure may result in metal fume fever, causing symptoms like cough, chills, and muscle aches. To…

Welding A356-T6 aluminum involves managing the heat-affected zone (HAZ), which can lower mechanical properties. Popular methods are Gas Tungsten Arc Welding (GTAW) and Gas Metal Arc Welding (GMAW). Selecting the…

Welding 80/20 aluminum involves joining thin aluminum sections, often made from 6061-T6 or 7075 series. It requires removing anodized surfaces to ensure a strong bond. This aluminum offers excellent corrosion…

To weld 954 Aluminum Bronze, use nickel aluminum bronze filler wire to prevent cracking. Ideal methods are MIG and TIG welding; avoid oxyacetylene techniques. This alloy has strong tensile strength,…

Welding 7075 series aluminum presents challenges due to phase segregation. When heated, the combination of aluminum, zinc, magnesium, and copper can flow unevenly. This causes structural weaknesses and often results…