Posts Tagged ‘Aluminum Welding’

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Everything you ought to know as to how to weld Aluminum:

Friday, September 24th, 2010

Safety First:

When welding aluminum, wear all needed safety equipments. You should wear gloves, goggles, hearing protection and a heavy apron so that you can protect your body from spatters. Wear eye protection equipment to protect your eyes from ultraviolet rays. Make sure your work area is well ventilated so that fumes can be removed when welding. For precaution purpose, keep your face away from fumes as far as possible.

Material preparation:

• Clean away all the lubricants.
• Remove aluminum oxide from the surface of the metal with the help of a metal brush.
• Do not use a brush that is used in other materials.
• While pre-heating is not compulsory, if you’re welding two pieces of different gauge aluminum, pre-heating can help prevent some problems.
• While pre-heating aluminum, it should not exceed 230 degrees F.

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How to weld aluminum in a safe way:

Monday, August 30th, 2010

Aluminum can be welded either with a wire feed welder or stick welding. To avoid injury, use these safety measures:

• Wear a protective welding hood while welding aluminum.

• It is important that you wear safety equipments like thick leather welding gloves, long jeans and boots and welding jacket to protect yourself against sparks and heat caused by welding.

• After welding work is over for the day, clean the work area as it can reduce the risk of fire caused by sparks.

• Always route the welding leads from welder to steel so that nobody can trip on them.

• Before a technician starts the aluminum welding process, ensure that all the cords and welding leads are free from defects.

• After welding work is over, turn off the welder.

• Clean up all the tools and materials used in this project so they don’t become a hazard.

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Aluminum welding and its uses:

Wednesday, August 4th, 2010

Aluminum welding is known as the most intractable alloy. These are done according to the grade and type of aluminum used. There are three types of aluminum where welding is done easily. There are commercial grade aluminum, non heat treatable alloy and heat treatable alloy. All these three contains some chemical which leads to easy welding. The first two types consist of pure aluminum and magnesium respectively. Where else heat treatable alloy contains copper, zinc, magnesium or silicon which makes the work of welding difficult. Due to copper you may find crack on the metal while welding.

These generally include Mig welding and Tig welding method during welding. For better result the latest technique used by aluminum welding is the combination of mig welding with arc welding. These welding feed the rod faster than other types of welding. This welds the metal quicker without stopping for brushing or grind. There are few factors which will affect aluminum while welding are the coating of aluminum oxide, conductivity and expansion of thermal and characteristics of melting.

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USES OF TIG WELDING TUNGSTEN ELECTRODES

Wednesday, June 30th, 2010

An electrode is used to make some contact with metals and used as consumables in welding process. Tungsten is a metal which is found naturally and used in many high temperature applications. Because of its hardness and density it is widely used in welding process. Thoriated tungsten electrodes are mostly used in tig welding process. Thorium which is abundantly found and less cost is used to improve the melting temperature and improve arc stability in tig welding process. The uses of thoriated tungsten electrodes are

• It make good welds and quite easy to use
• It operates well below its melting temperature
• Low rate of consumption of electrode
• It reduces the weld metal contamination and initiate the arc easily
• It has high current carrying capacity and sharpen the electrodes
• It has long life with high quality and suitable for all steels.

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What welding helmet used for?

Wednesday, June 23rd, 2010

Welding helmet is very important and necessary while welding metals. You should weld the metals without a helmet. 50 % of workers are injured for not wearing welding helmet. The helmets are worn because while weld a spark and other lights are thrown out. The role of this helmet is to protect your face and of course eyes. It is important to protect your eyes because once your retina is damaged you can become blind.

Have your helmet and other gears in an approachable distance. These helmets are vulnerable which protects from rays and doesn’t cause any damages on it. The welding helmet consists of lens shade which protects the eyes. The lens is made out of electronic shutter which adjust automatically while welding. They are generally used while working with all the arc metal welding equipment. When you buy the helmet make sure they are light weighted helmet. Heavy helmet can be tiring to wear and these can strains your neck. There are many kinds of helmet but buy a quality helmet which last for longer period.

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Aluminum Welding: Tips For A Good Weld

Wednesday, October 21st, 2009

The most complicated alloy is aluminum. The metal is with good grace accessible in the market. They are available in various forms of product. Firstly aluminum oxide ought to be removed from the surface of the metal. Aluminum welding is difficult to perform. The main issue with aluminum is that it gets heated up real quickly. The metal’s melting point is very low. Therefore certain measure ought to be taken to make aluminum welding easy. Here are a few essential tips to achieve this;

  • Preheat it with the help of a blowtorch. This curtails distortion.
  • TIG welder can be very expensive. Go in for MIG welding if you run short of money.
  • The most appealing feature of the metal is that it has low density. It is terrific
    conductor electricity.
  • Utilize a heat sink as the metal picks up heat swiftly.
  • Keep an eye on the metal slides. They have got to be tight as one while you
    weld.
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TIG Weld Can Repair Aluminum

Tuesday, September 15th, 2009

You can repair your aluminum trucks with the help of TIG welding process.

You can repair cracks and fill holes of trucks with the help of TIG. TIG Welding can repair aluminum. To ensure arc stability, you should use a power source with high frequency capabilities. Most TIG welding repairs done on aluminum will not exceed 80-150 amps, so a 200-amp power source matched to a 200-amp air or water cooled TIG torch will suffice.

Shielding Gas:
For aluminum welding purpose, argon gas can be used. An argon/Helium mix can weld thicker materials; helium can create a hotter weld puddle.

Tungsten:
Pointed tungsten can easily start the arc and a narrow heat-affected zone, along with the ability to control penetration more accurately. 3/32-in diameter tungsten is adequate for most repairs but an 1/8-in diameter tungsten should be used on 3/8 inch or thicker aluminum.

Filler Metal:
The most common thickness of the filler rod is 3/32-in and 1/8-in diameter. Always use Scotch Brite TM pad to clean the filler rod before welding. Do not use a sandpaper to clean dirty filler as this could add alumina sand to the filler.

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Guide to Aluminum Welding

Thursday, August 27th, 2009

Aluminum is the most difficult alloy. Initially, aluminum oxide should be cleaned from the surface. Heat treatable aluminum alloys receive their strength from a process called ageing. Notable decrease in tensile strength will happen when welding aluminum due to over-ageing.

Welding aluminum is very easy as it melts easily in low temperature and does not crack after solidifying. Aluminum welding is done according to the type of aluminum used like non-heat treatable alloys containing small amounts of manganese or magnesium and heat treatable alloys containing copper, silicon, zinc or magnesium. These types of aluminum can be welded easily but other metals like copper and lead are difficult to weld and often lead to crack while welding.

Different process of aluminum welding is TIG welding, MIG welding, gas, plasma, resistance welding etc. TIG Welding is best suited for welding pipes and repairing castings. MIG welding is best suited for welding thicker aluminum work pieces at a faster rate and for achieving long, continuous welds. Always clean the aluminum before welding, to remove the oxide layer. Use a stainless steel wire brush used for cleaning aluminum.

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Aluminum Welding

Monday, June 22nd, 2009

Some of the factors that affect the welding of aluminum are

  • Aluminum Oxide coating
  • Thermal conductivity
  • Thermal expansion Coefficient
  • Low melting temperature

Melting point of Aluminum oxide is nearly 1926 ° C. As the aluminum oxide film becomes thicker, it will start absorbing moisture from the air. Moisture is a source of hydrogen which is the cause of porosity in aluminum welds. Hydrogen can come from oil, paint, dirt, base metal, oxide, etc. Hydrogen will enter the weld pool and is soluble in molten aluminum. Hydrogen is rejected during solidification. Prior to welding, aluminum oxide film must be removed. If not, it may lead to reduction in ductility, lack of fusion and weld cracking.

Aluminum has a thermal conductivity which is about six times as fast as steel, which means more heat has to be put into aluminum even when the melting point is less than half that of steel.

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What You Should Know About Aluminum Welding

Tuesday, May 19th, 2009

We all know that the welding profession is one of science and patience. It requires some scientific knowledge to know which electrodes you will need to purchase for your job. You will need to have a slight bit of knowledge to be able to know what size you will need, what type of metal will work with which type of electrode. You will also need a vast amount of patience, especially if you are a beginner.

There are several types of welding processes along with different types of metals that can be welded. But, when it comes to aluminum welding process, it is most sensitive. You must apply the correct amount of heat to the welding source or experience burn through. You must make sure that your welding source material is free of any debris or other chemicals such as; aluminum oxide. Any chemicals left on the surface of the work material will deter the welder from producing the outcome desired, they may in fact bring about adverse effects to the work materials.

(more…)

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