Aluminum welding is one of the most critical processes in manufacturing. By understanding the challenges of aluminum welding, manufacturers can produce stronger and more reliable products. Aluminum is a unique material that requires special techniques to weld properly. It is valued for it’s lightness and is often used in aircraft construction. This guide will discuss the different steps involved in the aluminum welding process and why you must follow a specific protocol when welding with this material.
Challenges with Welding Aluminum
Aluminum is a beautiful metal that creates solid welds when the product is finished. It is a coveted metal because it has an excellent strength-to-weight ratio. However, getting that perfect finished product can be a challenge since aluminum is tricky to work. When welding with aluminum, welders will face the following challenges:
“Porosity most often occurs when the piece of aluminum has not been adequately cleaned”
Thickness: An accidental burn-through is a common problem when working with aluminum. A thin aluminum sheet will burn quickly, but a thick aluminum sheet needs to be tackled with a delicate hand and understanding its melting point. A successful weld combines experience and learning how to apply the correct heat depending on the unique metal thickness.
Impurities: Impurities in any metal can cause a poor well. Aluminum can be susceptible to impurities, so it must be accounted for during a weld.
Oxidation: Aluminum has a strong affinity for oxygen, and a hard, whitish layer will form on aluminum alloys. If aluminum oxidizes, it will have a higher melting point than aluminum alloys and must always be when welding on an oxidized piece.
Porosity: Most often occurs when the piece of aluminum has not been adequately cleaned, or the weld parameters are wrong or too cold. To avoid this, clean all materials and take your time working through each weld.
Proper Aluminum Welding Techniques
The first step to proper aluminum welding is understanding how to set up the equipment. Aluminum welding machines use a different wire and electrode than other metals, so the welder must also use a lower voltage and current than they would otherwise use (like when welding steel).
Once the machine is set up, the welder can prepare the metal for welding. Aluminum must be cleaned of all contaminants before beginning the weld. This includes oil, grease, dirt, oxides, and any other materials that could prevent the weld from taking hold. After cleaning the metal, it’s time to start welding, but aluminum welding must be done quickly and efficiently of the narrow workability window.
Once the equipment is set up, and the weld has started, the welder only has a small window of workability. Aluminum welders must be able to efficiently and quickly work the metal and welding machinery without slipping and damaging the surrounding materials. The only way to miTIGate the challenges of aluminum welding is to follow proper welding techniques to avoid cracking and warping the material.
Equipment Needed to Properly Weld Aluminum
Aluminum welding is a unique process that requires special techniques, equipment, and methods. There are three main processes used for welding aluminum: MIG welding, TIG welding, and stick welding. A competent welder will understand these techniques and know how to incorporate each welder for the optimal results. Essential aluminum welding equipment that a welder should know how to operate include:
MIG Welder: MIG welding uses aluminum wire to create the weld. This type of welder is easy to use and great for most aluminum applications.
TIG Welder: TIG welding uses heat and electricity to weld aluminum together. This type of welder gives you more control over the weld, making it helpful when welding thinner aluminum pieces.
Stick Welder: Stick welding is an option for aluminum repairs but is not typically used to weld main pieces. This type of welding uses a special aluminum rod that helps fill in any gaps in the weld.
Do you need both a TIG and TIG welder when working with aluminum?
You don’t need both welding machines to work on aluminum welds, but one of them is more suitable for aluminum’s unique welding challenges. So while you could weld aluminum with either a TIG or a MIG welder for your work – reaching for the TIG welder should be the first choice.
A TIG welder is the preferred choice for complex welding tasks involved with aluminum because the TIG welder gives the welder more control over the weld. This is especially important when welding thin pieces of aluminum together, which are notoriously finicky.
Rent Professional Aluminum Welding Equipment At Red-D-Arc
Despite the challenges, welding aluminum is an essential requirement for manufacturers. Aluminum is a lightweight but strong material that is perfect for many applications. When welded correctly, aluminum products are strong and durable. In addition, aluminum is resistant to corrosion and rusting, making it ideal for outdoor applications. Aluminum is an essential construction material in many industries beyond manufacturing, such as aerospace and automotive, there is no lack of products that need welded aluminum products.
If you are looking to upgrade your current welding fleet, or are starting from scratch and wanting to rent welding machines, Red-D-Arc offers a variety of equipment. From making that perfect weld with our D550K TIG Welder, to fixing imperfections with our ES275i Stick Welder
Red-D-Arc offers top-of-the-line equipment, for rent, lease or sale. For more information or to get a quote, give us a call at 866-733-3272 or contact us online.
