Aluminum Welding

The aluminum welding technology area has instructions, tips, and product information geared specifically toward welding this lightweight, versatile material.

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Aluminum Workshop: Taming 6061-T anodized tubing

November 14, 2014

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Q: I’m having a very difficult time welding 6061-T aluminum tubing that has been anodized. The weld won’t flow out correctly, I can see a lot of porosity, and the weld has a black color to it. What can I do to make the weld better? A: The problem you are describing is a common one. Let’s...

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Aluminum Workshop: What’s so bad about welding 7075, 2024?

November 12, 2014

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Q: You have discussed previously the fact that some aluminum alloys, such as 7075 and 2024, should not be welded. But I know a fabricator who occasionally welds 7075. Is he engaging in a poor practice, or is there something I don’t understand? A: I can’t really answer your question...

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Aluminum Workshop: Don’t know the alloy? Make an educated guess

November 12, 2014

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Q: I need to repair an aluminum casting, but I have no idea what specific alloy it is. What filler metal should I choose? A: You can’t tell what an aluminum alloy is just by looking at it. Realistically, you’ll probably have to choose the filler alloy without being sure which casting alloy you...

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Aluminum Workshop: The burning question behind welding aluminum with FCAW/SAW

November 11, 2014

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Q: I heard recently that there is a flux-cored wire available for aluminum GMAW. Is this true? If so, can you tell me who makes it? Also, why isn’t flux-cored wire more commonly available for aluminum GMAW? A: First of all, as far as I know, there is no flux-cored wire available for aluminum...

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Aluminum Workshop: Differentiating between residue and oxide on your aluminum wire

November 10, 2014

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Q: I think I have a problem with the 5356 aluminum wire I am using for gas metal arc welding (GMAW). If I take a clean white cloth, wrap it around a length of the wire, and rub it vigorously, I get a pretty big black mark on the cloth. I think the wire is dirty. The company that sold it to me says...

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Aluminum Workshop: Sizing up processes, power source capabilities for aluminum welding

November 7, 2014

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Q: I have a small shop at my home and would like to add a piece of welding equipment to increase my capabilities to weld aluminum. But, I’m confused. I don’t know whether to buy a gas tungsten arc welding (GTAW) machine or a gas metal arc welding (GMAW) machine. Any suggestions? A: In general,...

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Aluminum Workshop: Aluminum TIG with DCEN

November 6, 2014

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Q: I do a lot of aluminum GTAW, and I have always used alternating current (AC). Recently a friend told me that I can GTAW aluminum using direct current electrode negative (DCEN). Is this true? A: Yes, it is true, but using DCEN requires some changes in the process. Let’s find out what they are....

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Aluminum Workshop: Choosing tungsten for aluminum TIG

November 5, 2014

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Q: I am just getting into aluminum GTAW and I have heard many recommendations about which tungsten electrode I should use. Can you tell me how to make the right choice? A: I will certainly try. First, let’s look at the commonly available tungsten electrodes (see Figure 1). Each type is given an...

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Aluminum Workshop: Busting the universal filler myth

November 4, 2014

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Q: My friend told me that he never worries about what grade of aluminum alloy he is welding on. He always uses 1100 filler. He says since 1100 is essentially pure aluminum and doesn’t contain any alloying elements, that you can use it to weld any aluminum alloy. Is this true? It would eliminate a...

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PWTV: GMAW Pulsed-Spray

Practical Welding Today®

Length: 17:08

Todd Bridigum, welding instructor at Minneapolis Community and Technical College, and author of, "How to Weld," tackles the basics behind pulsed-spray transfer mode.

PWTV: GMAW Aluminum

Practical Welding Today®

Length: 16:00

Todd Bridigum, welding instructor at Minneapolis Community and Technical College, and author of, "How to Weld," explains the art of aluminum GMAW.

Aluminum GMAW push-pull welding system targets truck trailer manufacturing

June 10, 2014

The POWER MIG® 350MP Trailer Manufacturing One-Pak™ from Lincoln Electric provides push-pull wire feeding capability for trailer manufacturing sheet metal applications. The multiprocess package includes a Magnum® PRO AL air-cooled, push-pull gun; aluminum drive roll kits; SuperGlaze 5356...

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PWTV: Aluminum Welding Principles

Practical Welding Today®

Length: 12:45

Todd Bridigum, welding instructor at Minneapolis Community and Technical College and author of, “How to Weld,” provides an overview of the various principles behind welding aluminum successfully.

PWTV: Aluminum TIG welding

Practical Welding Today®

Length: 34:00

In this episode, Todd Bridigum, welding instructor at Minneapolis Community and Technical College and author of, “How to Weld,” focuses specifically on aluminum TIG welding.

Optimize your welding processes with the right gas and expertise

Date: Wednesday, July 30, 2014 1:00 PM (CST)

Sponsored by Air Products

Length: 43:00

Air Products brings welding expertise and optimal performance to your shop floor. You'll see a live demonstration of our MAXX™ shielding gas blends and how they compare to a traditional industry standard gas blend.