Aluminum welding
Aluminum welding is used to bond together aluminum materials such as water pipes and tanks. This method uses a flux that contains aluminum and other elements. Aluminum has high thermal conductivity properties and helps the temperature stay constant. This process prevents any oxidation from occurring. Also, this type of welding requires special equipment. After it is done, the welded material is heat-treated and then tested to ensure its quality.
Definition of Aluminum
The aluminum element is used in the production of many different products including cookware, beverage cans, and even jewelry. Aluminum is also used in the manufacture of various types of metal alloys that are commonly used in the automotive industry. Aluminum is a lightweight metal that is relatively inexpensive and easy to work with. In addition to its use in manufacturing, aluminum has been proven to have some beneficial properties.
Type of Welding that you need to know
Welding is the process of joining two pieces of metal together using heat and pressure. This can either be done manually or automatically using a welder. There are several different types of aluminum welding processes including MIG welding: gas tungsten aluminum arc welding (GTAW), gas metal arc aluminum welding (GMAW), submerged arc aluminum welding (SAW), flux-cored arc aluminum welding (FCAW), and shielded metal arc welding (SMAW) or TIG welding.
TIG welding is a type of welding process where an electric current passes through a filler material, producing an arc between the electrode and base metals. The filler material is usually supplied from a wire reel or stick that is continuously fed into the weld puddle. The filler material melts due to the high temperature created by the arc and then solidifies rapidly. TIG welding is mainly used for spot welding applications.
How to do aluminum welding
The first step in welding aluminum is cleaning the surface of both pieces of material. This can be done using sandpaper or wire brushes. Sandpaper works well if the surface is smooth, but wire brushes are better suited for rough surfaces. Once the surface is clean, coat the area where the two pieces will touch with flux. Flux helps create a strong bond between the two metals. After coating the area, wait about 15 minutes before applying heat. Heat should only be applied to the joint, not the entire piece of aluminum. If too much heat is applied, the weld may crack. Apply heat using either gas tungsten arc welding (GTAW), shielded metal arc welding (SMAW), or plasma cutting. GTAW produces a bright yellow flame while SMAW uses a blue flame. Plasma cutting uses a high-temperature torch to cut through the metal.
Once the weld is complete, remove the excess metal using a grinder. Grinding removes any excess weld material and creates a smoother surface. Cleaning the welded area with water will help prevent rust from forming.
TIG welding is a type of welding process where an electric current passes through a filler material, producing an arc between the electrode and base metals. The filler material is usually supplied from a wire reel or stick that is continuously fed into the weld puddle. The filler material melts due to the high temperature created by the arc and then solidifies rapidly. TIG welding is mainly used for spot welding applications.
Welding detailed technique
With practice, a beginner can grasp the process from arc induction to the end of the arc, as well as how to hold the torch and filler bar at the right angle.
Electrode
The Tungsten electrode for aluminum or magnesium-aluminum alloy welding is a round tip with a tapered tip for welding steel Carbon or stainless steel Once the correct electrode is selected, install the electrode in the torch. Pay attention that the tip of the electrode protrudes about 3.2mm.
Protective gas
Argon gas, with good cleaning and penetration properties, is the gas of choice most commonly used for aluminum welding. 75% helium – will minimize magnesium oxide formation.
Arc bait
When using AC or DC with additional high frequency, the arc can be created without contact between the electrode and the solder, it is generated due to the high-frequency voltage.
Like in manual arc welding, the arc can form itself before reaching the required arc length. The arc is primed near the starting point of the welding line until a pool of molten metal appears. Light has a certain size, then start to move the torch to the end of the weld.
When welding with DC without the addition of high frequency, to cause the arc, we must apply electrodes to the solder. In this case, a tungsten-thorium type electrode should be used. To limit damage when arc priming, especially when welding aluminum, you must primer on a copper priming block.
Arc length
When TIG welding aluminum, for most metals, the most suitable arc length is 1.5 times the electrode diameter. The shorter the arc length, the narrower the weld, and the greater the depth of penetration due to the more concentrated arc heat. As the arc length increases, thermal concentration decreases resulting in reduced penetration depth.
Arc cutoff
Before the arc disconnection, the welding speed must be increased to avoid concave cracks at the end of the weld. Many people often apply the method of re-arcing right after breaking to melt the auxiliary metal to fill the indentation.
The angle of inclination of the torch
For a butt weld, the angle is about 90 degrees. However, it is generally advisable to let the torch tilt at an angle of 600 from the horizontal in the direction of displacement and the inclination of the secondary metal wall to be less than 200 horizontally. 450 both surfaces (i.e., at a right angle bisector (and inclined 50 to 150 in the welding direction).
When the thickness of the weld is not equal, the set point of the torch slightly deviates towards the thicker sheet to provide a balanced degree of melting. Aluminum welding needs to be done “hot and fast”. Unlike steel, aluminum’s high thermal conductivity requires a greater welding voltage, large welding current, and greater torch travel speed. If the movement of the torch is slow, it may lead to burn-through to the weld, especially when welding thin parts.
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