The Lincoln Electric Company

Frank Armao

Contributing Writer
The Lincoln Electric Company
22801 St. Clair Ave.
Cleveland, OH 44117


Phone: 216-481-8100
fax: 216-486-1751
www.lincolnelectric.com
Contact via email
He is a member of the AWS D1 Committee, chairman of the AWS D1 Aluminum Subcommittee, and vice chairman of the AWS D8G Automotive Aluminum Arc Welding Committee.

Aluminum Workshop: Why it’s so hard to weld anodized aluminum

January 20, 2015

By:

Q: I bought some anodized 6061-T6 tubing to make a structural framework and I’m having trouble welding it. The welds are black and ugly. Can you help? A: I think I can help. First, it would be helpful to explain what anodizing is. Anodizing is a reverse plating operation of sorts in which the...

Continue Reading

Aluminum Workshop: Welding 6061-T6 without filler metal; choosing shielding gas for GMAW

January 6, 2015

By:

Q: I’m trying to use gas tungsten arc welding (GTAW) without filler metal to join 6061-T6, and almost every weld I make cracks. What’s going on? A: A common aluminum alloy, 6061-T6 is welded every day, so we assume it must be easy to weld. Unfortunately, it isn’t. In fact, 6061 and the other...

Continue Reading

Aluminum Workshop: Welding anodized 6061-T6 extruded tubing, 7075 series aluminum

January 6, 2015

By:

Q: I bought anodized 6061-T6 extruded tubing and have been trying to gas tungsten arc weld (GTAW) if, but the results so far haven’t been satisfactory. The welds look black and porous. I’m an experienced welder, and I’ve welded aluminum before, but I’ve never run into this. Is there...

Continue Reading

Aluminum Workshop: Choosing an aluminum alloy

January 5, 2015

By:

Q: I have a project I want to build from aluminum sheet and extrusions. Some of my friends tell me to make it entirely from 6061-T6. Other tell me to use other alloys, mostly 5000 series. The project entails a lot of welding. Which alloy should I use? A: Without knowing more details about your...

Continue Reading

Aluminum Workshop: Defining cast and helix

January 5, 2015

By:

Q: What are cast and helix? I keep hearing about them, but no one seems to really know what they are. A: First of all, cast and helix are two separate attributes of spooled wires intended for gas metal arc welding (GMAW). The terms have no meaning for straight cut lengths of wire meant for gas...

Continue Reading

Aluminum Workshop: Understanding AC and HAZ ‘cracks’

January 2, 2015

By:

Q: I know that when aluminum alloys are gas tungsten arc-welded (GTAW), usually we use alternating current (AC) because it give some sort of cleaning action. Can you explain what it is and how it works? A: Sure, let’s try. But before I start, let me admit that this explanation is a bit of a...

Continue Reading

Aluminum Workshop: Defining arc rectification

January 2, 2015

By:

Q: Sometimes when I’m AC gas tungsten arc welding (GTAW) aluminum, the arc will start to flutter for a while. I can see it and hear it. Usually it goes away after a few seconds. What’s going on? A: First of all, the good news is that you’re not imagining it. This phenomenon is fairly common...

Continue Reading

Aluminum Workshop: Using 4043 versus 4047 filler wire

December 30, 2014

By:

Q: I usually use 4043 filler wire for welding 6061-T6 and castings. My friend told me I should switch to 4047 because it’s stronger. Is that true? It’s more expensive than 4043. Is it worth it? A: As you know, 4043 and 5356 are the most common aluminum filler alloys. In fact, these two alloys...

Continue Reading

Aluminum Workshop: Cleaning aluminum before welding

December 29, 2014

By:

Q: What’s the best way to clean aluminum before welding? How long can I wait to weld it before it needs to be cleaned again? A: Preweld cleaning requires two operations: oil and grease removal and oxide removal. Before you do anything else, remove any oil, grease, or water vapor from the...

Continue Reading

Aluminum Workshop: Fabricating aluminum plant boxes

December 29, 2014

By:

Q: I am bidding on a job to fabricate aluminum plant boxes. They will sit inside 4-foot-tall walls in an office. These rectangular boxes, or troughs, will be 7.5 inches tall, 7.5 in. wide, and 48 in. long, placed end-to-end to form 16-ft. dividers. I plan to use 5052 aluminum. A 1.75-in. flange,...

Continue Reading

Aluminum Workshop: Passing tensile tests for 6061-T6

December 26, 2014

By:

Q: I am having problems passing the tensile tests for my procedure qualification of aluminum alloy 6061-T6 on 6-inch-diameter pipe, Schedule 120. I am using ER4043 filler metal for a gas tungsten arc welding (GTAW)-gas metal arc welding (GMAW) combination process on the first joint and ER5363 on...

Continue Reading

Aluminum Workshop: Aluminum arc welding with other processes

December 26, 2014

By:

Q: Columnist’s Note: This issue’s column addresses several questions subscribers have asked about shielded metal arc welding (SMAW) of aluminum. Some of you asked about a flux cored welding (FCAW) wire for aluminum and where to get it. Others asked whether aluminum has ever been submerged arc...

Continue Reading

Aluminum Workshop: Arc blow, contact tips

December 24, 2014

By:

Q: Is it possible to encounter arc blow when welding aluminum? Since aluminum isn’t magnetic, I don’t think so, but my friend thinks it is. A cup of coffee is riding on your answer. A: It looks like you’d better get ready to pay up. It is possible to encounter arc blow when welding aluminum....

Continue Reading

Aluminum Workshop: An introduction to pulsed MIG power supplies

December 19, 2014

By:

Q: What’s the story behind pulsed gas metal arc welding (GMAW) aluminum? Some think it’s great, but others say it’s just a way for equipment makers to sell expensive power supplies. A: GMAW transfers metal in three ways. At low currents, you get short-circuit transfer, in which the molten...

Continue Reading

Aluminum Workshop: TIG welding and radio frequency interface

December 18, 2014

By:

Q: When I gas tungsten arc-weld aluminum using AC, my portable radio speakers buzz. Does the high frequency that stabilizes the arc cause this? Will it hurt the radio or other electrical equipment? Can I shield adjacent equipment or minimize the effects? A: The high frequency (HF) that...

Continue Reading