Gas-metal-arc welding (GMAW) is a common method of welding aluminum alloys

Author: admin / 2024-05-02

How to Weld Aluminum Welding Wire

Aluminum Welding Wire
Gas-metal-arc welding (GMAW) is a common method of welding aluminum alloys. However, compared to steel, the low aluminum melting temperature and high thermal conductivity can make the material susceptible to burning through if welders don’t follow certain procedures. To ensure high-quality welds, welders must prepare the base metal and use the right type of filler wire for each job. To get the best results from this method, welders must also select a wire with a diameter appropriate for aluminum, as well as maintain proper welding techniques and shielding gas coverage.

The first step in successful aluminum welding is to clean the surface of the workpiece before welding. This will remove any oil or grit that could contaminate the weld. A stainless steel wire brush is ideal for this task as it can be used without scratching or damaging the aluminum. Once the workpiece is cleaned, it should be rinsed and dried to prevent contamination of the weld.

Next, welders must ensure that their welding equipment is compatible with aluminum welding. To do this, they must check the shielding gas coverage of their machine to ensure that it is pure argon. Some machines may offer the option to add helium to the shielding gas, which can help with arc start and stability. However, pure argon is recommended for aluminum welding to achieve superior weld quality.

Welders must also change the drive roll on their welding gun for aluminum. Since the soft aluminum wire is softer than steel, it tends to tangle and erode more quickly on drive rolls with higher friction. Using plastic or Teflon liners will minimize this problem, as will keeping the gun cable as close to the drive rolls as possible to reduce wire-feed resistance and birdnesting.

Some welders may find it easier to use a spool gun for aluminum welding. This device allows welders to keep their standard welding gun loaded with steel and then switch to a spool gun for aluminum when needed. This can be helpful to reduce downtime and the cost of changing out guns.

When using a MIG welding gun for aluminum, welders must adjust their welding parameters to accommodate the lower melting point of the material. This includes increasing the travel speed to compensate for the lower weldability of the material. They should also use a longer wire stick out, as the spray transfer technique used for aluminum welding causes the wire to heat much faster than steel. A 1" stickout is typically recommended. Additionally, it’s important to use a wire feed that has series-specific tension settings to eliminate birdnesting and other feeding problems.