Choosing the correct Aluminum TIG Wire and properly adjusting all of your welding settings is key to creating strong

Author: admin / 2023-11-09

Choosing Aluminum TIG Wire and Filler Rods

Choosing the correct Aluminum TIG Wire and properly adjusting all of your welding settings is key to creating strong, beautiful welds. This can feel overwhelming at first, but with experience, it becomes second nature. There are many variables to consider, including the metal being welded, the welding application, the welder itself, and even the weather conditions. When it comes to TIG welding with aluminum, there are also several factors to take into consideration when selecting a particular filler rod, such as the alloy, diameter and whether it's heat treatable or not.

When it comes to selecting the right diameter rod, it's a good rule of thumb to choose a filler rod that is slightly thinner than the thickness of the metal you are welding. This prevents the rod from "balling" before it reaches the weld puddle. A large rod will chill the puddle, which can result in an irregular bead. In addition, if the rod is too thin, it will ball before reaching the puddle, which may cause it to burn through and leave gaps in your weld.

Aluminum TIG welding requires a relatively high current (amperage). For this reason, it's important to have an appropriately sized machine to ensure that you can deliver enough power to the workpiece. An undersized machine will not be able to provide enough amps, which can lead to poor weld quality and possibly damage the machine itself.

When selecting an aluminum TIG wire, look for a high-quality, eutectic alloy, which is designed to provide consistent penetration and quality welds. Look for a rod with a high magnesium content, which helps promote a clean, stable weld pool and provides excellent crack resistance and ductility. In addition, select a rod with a low silicon content, which minimizes the weld defect known as slag inclusions.

Both 4043 and 5356 alloys are non-heat treatable, however, when used in the argon/helium mix for TIG welding aluminum, they are capable of being worked hardened after the weld to improve their strength and ductility. Non-heat treatable aluminum weld rods are typically recommended for applications where a smooth, shiny finish is desired.

When handling your aluminum welding rod, make sure to keep it away from moisture and oils. It's best to store it in a plastic bag or box. In addition, ensure that your contact tip is sized correctly for the type of rod you are using. Ideally, the tip should be marked with an "A" for aluminum and be oversized to allow for easy, smooth wire feeding. Also, be sure to bring the rod into your welding area at least 24 hours before you plan on welding with it so that it can acclimate to the temperature of your work area. This will help avoid contamination that can produce porosity in the weld. Lastly, be sure to store your aluminum welding rods in a dry location that's free from temperature fluctuations. If possible, keep them separate from your steel welding rods to prevent contaminating one with the other.