Welding on Aluminum

Many professional welders say that aluminum is the hardest metal to weld on because they are alloys and have many physical and chemical properties that are to be understood before they can be worked with effectively.

Some of the properties that make aluminum harder to work with are the fact that it is difficult to see. There is no color change to see when it is heated and it has a wider range of melting temperatures than other metals. The oxide in the aluminum also has different characteristics and the thermal, electrical and other characteristics like nonmagnetic are different.

This means that an individual working with aluminum must know what to expect with this metal before they begin. Some of the things to know are included here:

Melting point of aluminum oxide -- it is important to know that aluminum oxide has a higher point of melting than the base alloys. In fact, it doesn't melt until it reaches 3722 degrees Fahrenheit (2050 degrees Centigrade). You will also get a fusion that is incomplete if you don't displace the oxide.

When aluminum isn't welded correctly taking into consideration these different properties, the weld can crack, break or shrivel in size. This is what makes it so difficult to figure out how to do it. The effect of hydrogen on aluminum -- although hydrogen dissolves quickly when aluminum is in its molten stage, it has little solubility when the aluminum is solid which causes problems with porosity in the aluminum welds.

Higher electricity necessary -- if you are doing welding arc aluminum has to have a higher level of heat because it conducts electricity at higher level than other metals. This higher conduction of electricity allows the welder to use guns that contain longer contact tubes because the electrode doesn't get heated the way it does with ferrous electrodes.

Thermal conductivity is higher -- When you are working with aluminum the thermal conductivity is higher because it works with specific heat. In fact, it is about 6 times hotter than steel. This means that aluminum is more sensitive to the different heat fluctuations that the welding process can have and may make the metal crack or warp.

After taking this information in mind, most of the forms that you find aluminum in can be welded.

Tools you need There are a variety of tools you will need when working with aluminum, some of which are the same as you would use for any other type of metal. You'll need a TIG Welder (Tungsten Inert Gas Welder), a pair of good gloves, and a good helmet.

You will need a gas other than Argon by itself -- many welders say that a Argon and Helium mix works best. Aluminum welding rods of about 4043 seem to be best with aluminum, and it is important to use a steel brush for cleaning that you only use for aluminum.

Also, make sure to wear a cotton shirt for the work that is long sleeved. The reason is because the TIG welding process can produce more UV radiation and if you are not protected, it can burn you.


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