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How to weld aluminum?
Aluminum is a very special metal compared to iron and stainless steel, thanks to its high capacity to disperse heat and its lightness, which distinguishes it from other ferrous metals.
Aluminum can be welded with all the main types of welding techniques, such as MMA, MIG/MAG and TIG. However, each of these processes is more suitable for a particular application than another.
The question that you have to answer before welding aluminum is: what type of work do you have to do?
To weld aluminum with MMA electrode, for example, you need electrodes with an aluminum core and a special MMA generator that must have a high open-circuit voltage so that the welding arc will start without problems.
Aluminum electrodes require a higher amperage for the same diameter than normal rutile or basic electrodes. You need a high-end welding machine with a high work cycle to use them easily.
Aluminum electrode welding is used on thick plates, and never on thin ones, because the risk of "piercing" light metal plates is very high, since it uses high amperage.
Aluminum electrode welding cannot be defined as clean because, during electrode fusion, a lot of welding spots and slag are created, which can stain the base material.
Welding with aluminum electrodes is often used for rebuilding or surfacing material on repair parts that are finished or machined later.
How to use wire welding with aluminum?
Aluminum wire welding is very common in both industrial and private sectors.
This welding process is widely used because it makes it possible to weld thick parts even if the two joints are a little far apart.
Wire welding also makes it possible to weld thin parts using both the traditional MIG arc and the pulsed arc, used by many professional welders. The latter is used primarily in the industrial field and allows for less heat input and consequently less deformation of the welded piece.
Continuous wire welding is aesthetically pleasing with little welding spatter because the weld pool is constantly protected by the shielding gas (argon).
When wire welding aluminum, it is important to equip the welding machine with the right consumables and accessories to avoid problems with wire drag or poor-quality welds. The operator must use a cylinder of argon gas, replace the welding liner inside the torch, and change the roller and contact tips. The aluminum wire is in fact very soft and needs the above-mentioned precautions. It is then advisable to use a torch with a maximum length of 3 meters.
How can you weld aluminum?
Another very effective process for welding aluminum is TIG AC/DC welding.
This process takes advantage of the electric arc created between the infusible tungsten and the base material.
TIG welding gives a better aesthetic result because it leaves no slag and no spatter during the creation of the bead.
TIG welding is the most difficult to perform because it requires great skill in handling the torch to obtain a pleasant welding bead.
It is often done with both hands, one to hold the torch in the right position and the other to insert the rod of filler material into the weld pool to give strength and resistance to the joint.
It is necessary to use a TIG welding machine with AC/DC and high-frequency ignition, a TIG torch with tungsten electrode (the green one is the most commonly used), Argon gas to shield the weld pool during welding, and, of course, a ground cable.
It is important to remember that when welding aluminum with the TIG process, it is strongly discouraged to touch the base metal or weld pool with the tungsten tip because, besides ruining the electrode, the weld bead is damaged, compromising aesthetics and strength.
