Aluminum Welding

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

Filter Content

Aluminum Workshop: Guestimating aluminum alloys

November 18, 2014

By:

Q: If someone hands you a piece of aluminum, is there any easy way to tell what alloy it is? Everyone tells me I need to buy very expensive equipment to do this. A: Unfortunately, the people you are speaking with are correct. However, that’s assuming you need to know what alloy you have exactly....

Continue Reading

Aluminum Workshop: Where in the world is the 5052 filler alloy?

November 17, 2014

By:

Q: I am about to begin a project that requires me to weld a lot of 5052-O sheet material. There’s just one problem: I can’t find 5052 filler. Can you tell me why this is and what I should use instead? A: I can understand why you might think that you should weld 5052 sheet with 5052 filler...

Continue Reading

Aluminum Workshop: Taming 6061-T anodized tubing

November 14, 2014

By:

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...

Continue Reading

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

November 12, 2014

By:

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...

Continue Reading

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

November 12, 2014

By:

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...

Continue Reading

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

November 11, 2014

By:

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...

Continue Reading

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

November 10, 2014

By:

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...

Continue Reading

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

November 7, 2014

By:

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,...

Continue Reading

Aluminum Workshop: Aluminum TIG with DCEN

November 6, 2014

By:

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....

Continue Reading

Aluminum Workshop: Choosing tungsten for aluminum TIG

November 5, 2014

By:

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...

Continue Reading

Aluminum Workshop: Busting the universal filler myth

November 4, 2014

By:

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...

Continue Reading

PWTV: GMAW Pulsed-Spray

Presented by 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

Presented by 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...

Continue Reading

PWTV: Aluminum Welding Principles

Presented by 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.