Aluminum Tig Wire - How to Weld Strong, Attractive Welds

Author: admin / 2023-06-01

Aluminum Tig Wire - How to Weld Strong, Attractive Welds

TIG welding aluminum requires a certain degree of skill to produce strong, attractive welds. Getting the process right involves a number of variables, including the choice of filler rod and adjustment of machine settings. The correct choices can lead to a smoother arc, less porosity, and better weld performance in general.

Tungsten electrodes serve two functions: they create a stable arc and supply the energy needed for the welding process. They also serve as a shield, protecting the torch if it's struck against metal that would otherwise damage it. They are available in a variety of diameters, depending on the type of base material and thickness you'll be welding.

A welding rod is used to feed into the puddle, and it comes in several alloys for the different types of metal you'll be working with. It's important to use a rod that correctly matches the thickness of the material you're bonding. The rod's diameter should be slightly thinner than the material it will be welding, so it won't chill the puddle and cause an irregular bead.

The best rods for TIG welding aluminum are those with an AlMg binder. This is a high-strength aluminum alloy that's not heat-treatable and is often used in automotive components and bicycle frames.

Aluminum Welding Wire and MIG Welding Guns

Aluminum Welding Wire is a MIG (metal inert gas) wire that comes on a coil or spool and is fed into a compatible welding gun for GMAW (gas metal arc welding) tasks. It is available in a variety of diameters, including.030 inch and.035 inch, but you need to match your equipment with the proper aluminum welding wire for best results. This is because the soft aluminum wire is prone to kinking when it runs through a standard MIG gun designed for mild steel welding. Adding a spool gun or a graphene liner set to your MIG welder helps eliminate this problem and provides better feeding of the soft aluminum wire.

One of the biggest problems associated with MIG welding aluminum is its high conductivity, which rapidly pulls heat away from the puddle. This can result in burn-through or not forming a sufficiently large weld puddle. It also can reduce the amount of heat you are able to transfer from the electrode to the workpiece, which can affect weld strength and appearance.

When tackling your first aluminum weld, it is recommended to use a smaller electrode (typically a.030 in diameter). It's also a good idea to weld at a lower amperage setting, typically around 250 amps. This is to minimize your chance of introducing porosity and other defects into the weld, especially if you are inexperienced with the process.

Another important consideration is the proper storage of your filler metals. You should store them in a clean dry area that is close to the temperature of the welding area. Doing so will help prevent condensation from forming on the surface of the aluminum wire, which can cause it to oxidize and interfere with the welding arc.

Using the right MIG gun is essential for getting the most out of your aluminum welding capability. Many fabricators, home hobbyists, and repair professionals choose to complement their all-in-one MIG welder with a spool gun to simplify their aluminum welding tasks. These guns hold a 4-in-1 spool of aluminum wire and eliminate the birdnesting problems associated with pushing soft aluminum wire 10 to 15 feet through a regular gun. Spool guns also feature nylon inlet guides and liners that don't shave the wire as it passes through the drive rolls, reducing the chances of debris building up inside the liner.

There are two types of aluminum MIG welding wire available: ER4043 and ER5356. ER4043 is a popular choice for home hobbyists and repair professionals because it is easier to use than 5356, which requires more skill. The more expensive ER5356 has a higher tensile strength, is heat-treatable, and offers better corrosion resistance than other grades of aluminum MIG wire. This type of wire is commonly used on industrial and commercial projects like aircraft, cryogenic vessels, automobiles, and ship structures.