Even for those more experienced welders, learning how to weld aluminum can still be quite a challenge. Aluminum is versitile and light, permiting it to be used in many projects needing good finishes and strength. learning how to weld aluminum properly is therefore essential for those wishing to utilise the many advantages aluminum has.

Different features about aluminum such as a low melting point, a high conductivity and oxides coating on the milled product can cause complications. This is even more so when leaning how to weld aluminum sheet and pipe. This is where thourough preparation and proper equipment setup will pay off.

Weld Preparation

To weld aluminum effectively it must be prepared more diligently than if you to weld mild steel. Oils and grease needs to be removed with solvents and the oxide coating should be either brushed with a stainless steel wire brush or lightly ground with a sanding disk. Whatever is used should only be used on aluminum work and not mixed with steel as this will only cause contamination.

Mig Welding Aluminum

Learning how to weld aluminum with a mig welder is the easier process for beginners. Mig welders once set up are excellent for more structural projects such as boat building, gates, and light structural brackets and fittings.

If you use your mig welder also for welding steels, you will need to replace the inner cable liner and welding tip each time you switch processes, as the alloy weld will become contaminated with steel fragments by running aluminum wire through linners made for steel. aluminum liners are usually made of Teflon and should only be used for alloy welding wire.

Tig Welding Aluminum.

For more refined and decorative alloy welding the best method is Tig welding or GTAW.

Tig welding offers high quality welds that are strong and can be used without having any cleanup. Very small beads can be run for intricate work that requires a high quality finish. These are the types of weld you would see on bycikle frames and furniture.

Not only do you need to clean well before beginning, but you also should remove the smut or soot between  passes. This soot is fine particles of aluminum oxide and magnesium oxide. Proper welding techniques will minimize the amount of soot produced.

Shielding Gas

usually, 100 percent argon gas is preferred for aluminum GTAW, but when working with thicker materials, such as 1/2 inch or greater, add helium in the range of 25 to 50 percent. Helium makes the arc hotter and provides for more penetration.

Mig Torch and mig guns

if the application is light-duty fabrication requiring up to 150 amps, an air-cooled torch or hand piece may suffice. Higher-amperage jobs require a water-cooled torches and hand pieces. One feature to look for in a good torch is a flexible head, which offers maneuverability and reaches tight areas. Trying to access tight areas is a main drawback to using a mig set-up due to the size of the gun or hand piece.

When you learn how to weld aluminum, you can reduce the number of errors you make by learning  to set up your welder using proper gasses, wire feeds, and electrodes and using correct preparation of your work. Plus getting  advice from tutorials and more experienced welders. Soon, you will feel as confident welding aluminum as you do steel.