Aluminum Welding

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Aluminum Workshop: The truth about welding aluminum castings

March 23, 2017 | By Frank Armao

Q: A group of friends and I were talking the other day. Some people said that all aluminum castings are weldable. Others took the extreme opposite position and said that aluminum castings usually aren’t weldable. What’s the truth?A: The short answer is that, yes, most aluminum castings are...

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Aluminum Workshop: Choosing a filler to repair 356.0-T6 casting

January 30, 2017 | By Frank Armao

A reader wanting to make a repair to a 356.0-T6 aluminum cylinder gets Frank's advice on what filler metal to use.

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Aluminum Workshop: 6061-T6 cracking

November 30, 2016 | By Frank Armao

Q: My company recently purchased a piece of equipment fabricated from 6061-T6 structural shapes. The welds do not seem to be very good and we have found several cracked welds. However, it is the weld shown in the photo that is puzzling. This weld shows a crack in the 6061 base metal about 2 in....

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Aluminum Workshop: Know the Mg content of your 5XXX alloy

September 23, 2016 | By Frank Armao

This month’s topic doesn’t deal specifically with welding aluminum, but I think you will agree it has important implications in the design and fabrication of aluminum structures. This topic and its associated problems have come up in conversations twice in the past two months. It deals with...

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Aluminum Workshop: What are the advantages of AC in aluminum GMAW?

July 22, 2016 | By Frank Armao

Q: Lately I have seen a few welding equipment manufacturers offering gas metal arc welding (GMAW) power sources that use alternating current (AC) instead of the direct-current electrode-positive (DCEP) current. Can you tell me what, if any, advantages there are to using AC instead of the more...

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Hobart to offer aluminum welding technology seminars

July 5, 2016

Hobart will host a three-day Advanced Welding and Design workshop as part of its aluminum welding technology seminars. The program will be held at the Miller Electric Mfg. Co. Training Center in Appleton, Wis., Oct. 18-20, 2016. The program provides advanced technical and hands-on welding...

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Aluminum GMAW guide updated

June 1, 2016

Lincoln Electric has released an updated guide for aluminum GMAW. The manual features a new, reader-friendly layout with updated information and photos of products and processes. The guide offers a detailed look at filler metal types, filler metal selection considerations for welding, tips for...

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Resistance welding control features MFDC programming capabilities

May 23, 2016

The new Matuschek 1,000-Hz MFDC SPATZ+ is a modular resistance welding power supply and timer that can be configured for various purposes by changing or adding plug-in circuit boards. It can be used as a single weld gun controller, a multigun controller, a servo gun controller, and a master/slave...

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Aluminum Workshop: The perks of a push-pull gun for GMAW

May 12, 2016 | By Frank Armao

Q: I will be getting into aluminum welding much more than I have in the past. I want to buy a new set of equipment for gas metal arc welding (GMAW) and I’ve already picked out the power supply and feeder. Should I buy a push-pull gun or stick with the simpler and less expensive push-only gun? A:...

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Lincoln Electric to present aluminum welding seminar May 25-27

March 29, 2016

Lincoln Electric Co. will present a three-day Advanced Aluminum Welding Seminar at its Cleveland headquarters, May 25-27, 2016. The course, intended for welding engineers, technologists, technicians, and shop supervisors, will comprise about 70 percent classroom instruction and 30 percent...

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Aluminum Workshop: What not to do when excessive contact tip burnback occurs

March 28, 2016 | By Frank Armao

Editor’s Note: Part I appeared in the January/February 2016 issue of Practical Welding Today®.

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Aluminum Workshop: What not to do when excessive contact tip burnback occurs

January 29, 2016 | By Frank Armao

Frank Armao explains why contact tips are important in the welding process and what you shouldn't do to remedy burnback problems.

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Aluminum Workshop: Fine-line lack of fusion and its causes

November 16, 2015 | By Frank Armao

Q: I recently fabricated a large component from 1-in.-thick 5083 aluminum. The customer required it to be radiographed. His inspector failed one of the radiographs because of a lack of fusion (LOF) discontinuity. I looked at the radiograph and I can’t see any discontinuity. Could the inspector be...

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Ohio State-developed welding technique makes stronger welds using less energy

October 30, 2015

Engineers at The Ohio State University, Columbus, Ohio, have developed a new welding technique that consumes 80 percent less energy than a common welding technique, yet creates bonds that are 50 percent stronger. The new technique could have a significant effect on the auto industry, which is...

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Aluminum Workshop: Defining, stopping porosity in aluminum welds

September 28, 2015 | By Frank Armao

Q: I’m having quite a bit of trouble with porosity in my aluminum welds lately. Can you tell me the sort of measures I should take to minimize the porosity? A: Let’s first define the basic cause of weld porosity in aluminum and then go on to summarize the major causes. All porosity in...

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