The Challenges of Welding Aluminum
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Aluminum welding has become one of the most popular forms of welding in the industry today, with a special interest being in the automotive sector. Understanding how to successfully weld aluminum becomes the tricky part, as it is not the easiest material to work with. The process as a whole has its challenges, from preparation and correct welding techniques to specific equipment that should be used to help your operation run smoothly.
For this reason, aluminum requires specific attention to ensure your welding jobs are succesfully completed with minimal issues and ease.
Aluminum has certain properties which make it more challenging to weld than other metals. Its relatively high thermal conductivity (approx. 209 W/m K) and low melting point (660~670°C) make it such that only fusion welding processes can be used to weld it.
Fusion welding processes, such as MIG, TIG, Laser, and Electron Beam, generate intense heat in small area to melt the material in the desired weld area. This small heat affected zone is essential as aluminum&#;s high thermal conductivity tends to result in heat traveling throughout the work piece, either melting too much material or deforming the entire part. The amount of heat applied and the location to which it is applied must be controlled very precisely. Manual welding processes, such as MIG and TIG, rely on operator skill and heat sinking to control these factors. Because aluminum doesn&#;t change in appearance as it approaches its melting point, welding processes which require visual judgment of material readiness can be unreliable. Automated methods, such as Laser and Electron Beam, which use computers to control feed rate, power, and weld location, offer more precise and consistent weld quality
What is the best way to clean aluminum before welding?
Preweld cleaning requires two operations: oil/grease removal and oxide removal. As below, remove oils and greases first, then remove the oxide. Don&#;t reverse this order.
Take the following steps before welding aluminum:
1. Remove oil, grease, and water vapor using an organic solvent such as acetone or a mild alkaline solution like a strong soap. You may also use citrus-based degreasers, but be sure to rinse and dry the part before welding.
2. Remove surface oxides with a stainless steel wire brush (used only for aluminum) or strong alkaline or acid. Many welding suppliers sell oxide-removal solutions in spray or squeeze bottles for local application. Exercise extreme care when handling these solutions, and again, rinse and dry the part before welding.
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3. Assemble the joint. If it won't be welded immediately, cover the joint with brown Kraft paper to prevent dirt and grit in the air from getting into the joint.
4. Keep the aluminum dry and at room temperature.
5. Weld within a few days. Clean the joint again if it isn't welded within that time.
View Lincoln Electric Aluminum MIG and TIG Welding Products
View More Aluminum Welding How-To Articles
View Aluminum Process and Theory Articles
Published with permission from Practical Welding Today Magazine, Sept/Oct Edition
Customer Assistance Policy
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for information or advice about their use of our products. Our employees respond to inquiries to the best of their ability based on information provided to them by the customers and the knowledge they may have concerning the application. Our employees, however, are not in a position to verify the information provided or to evaluate the engineering requirements for the particular weldment. Accordingly, Lincoln Electric does not warrant or guarantee or assume any liability with respect to such information or advice. Moreover, the provision of such information or advice does not create, expand, or alter any warranty on our products. Any express or implied warranty that might arise from the information or advice, including any implied warranty of merchantability or any warranty of fitness for any customers&#; particular purpose is specifically disclaimed.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.
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