HOW TO WELD ALUMINUM
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Even for the most experienced welders, welding aluminum can present a challenge. Aluminum welding requires different techniques and processes than welding steel, and it’s critical to know these differences in order to complete successful welds and work on a variety of different projects.
While welding aluminum can be difficult, it’s a skill that can be developed with the right knowledge and practice. Keep reading to learn all about how to weld aluminum—from the different types of welding you can use to general tips for success.
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Aluminum is a common type of metal used in fabrication. It’s non-corrosive, lightweight and pleasing to the eye, making it an ideal choice of material for a wide variety of welds. However, the same traits that make aluminum desirable can also make it tricky to work with.
So why is aluminum so difficult to weld? This material is soft, highly sensitive and is insulated by a tough oxidized layer. While in its molten state, aluminum is susceptible to impurities, which can lead to porous, weak welds.
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Aluminum and its alloys have a great affinity for oxygen. Pure aluminum melts at 1,200°F (650°C), and the oxide that protects the metal melts at 3,700°F (2,037°C). Because the oxide melts at a temperature approximately 2,500°F (1,370°C) higher than the aluminum itself, the oxide must be cleaned from the metal before welding can begin.
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Since aluminum has a higher thermal conductivity and low melting point, it has a smaller window of workability than other metals and can easily lead to burnthrough. This, in combination with it being harder to indicate weld progress and quality, can make aluminum a difficult material to work with.
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@jonsmaradona said in HOW TO WELD ALUMINUM:
Even for the most experienced welders, welding aluminum can present a challenge. Aluminum welding requires different techniques and processes than welding steel, and it’s critical to know these differences in order to complete successful welds and work on a variety of different projects.
While welding aluminum can be difficult, it’s a skill that can be developed with the right knowledge and practice. Keep reading to learn all about how to weld aluminum—from the different types of welding you can use to general tips for success.
On top of aluminum sits an aluminum oxide layer, which melts at a significantly higher temperature than aluminum. Melting through this layer requires high heat, however, the welder must be careful to not burn holes in the aluminum underneath.
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@donaldrsimonn said in HOW TO WELD ALUMINUM:
Since aluminum has a higher thermal conductivity and low melting point, it has a smaller window of workability than other metals and can easily lead to burnthrough. This, in combination with it being harder to indicate weld progress and quality, can make aluminum a difficult material to work with.
As aluminum is very sensitive, there are several ways it can become contaminated by dirt, air and water during the welding process. Aluminum can become contaminated by air that reaches the weld because of poor shielding or excessively long arcs. Oxygen can reduce aluminum’s strength, ductility and cause an oxide formation on aluminum welds, which affects its appearance and complicates multipass welding. Hydrogen can come from many sources, such as moisture in electrode fluxes, humid air, damp weld joints and more. For all of these reasons, it’s important to clean aluminum thoroughly and store it correctly prior to welding.
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Welding aluminum is more difficult than welding steel, but you are much more likely to create quality welds if you learn the basics. MIG welding aluminum is easier than TIG welding aluminum, and it requires less costly equipment. https://proqm.com.au/women-in-construction-mentorship-program/
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@tamiloneindia I understand your point and I know very well that aluminum welding is always been a challenge for most welders either it's tig or mig but the context is same for everyone. I'm stuck with aluminum pipe cutting and don't know how to cut aluminum pipe properly without having any type of crack. As per this blog source, it's possible to cut aluminum with angle grinder, router, chop saw, jigsaw, plasma cutter, and mitter saw.
What you say?
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Great reading your advice in here!
