Aluminum welding is challenging due to the metal’s physical factors. Proper cleaning and equipment use are important for safety. TIG welders are commonly used, but finding the right temperature and speed is difficult. Cleaning aluminum oxide is crucial for a smooth weld. Safety precautions, including protective clothing, are necessary due to the high amount of UV rays emitted by TIG welders.
Aluminum welding is the process of fusing two pieces of aluminum together using high heat. This process is considered one of the more difficult welds to make due to the physical factors of the metal. One of the most important steps in creating this weld is proper cleaning and also proper use of the welding equipment. Welding equipment, however, poses a serious threat to user safety.
The aluminum welding process is traditionally done with a TIG welder that uses a separate roll of wire to create the weld, essentially welding the wire and metals together. A welding machine works by feeding argon gas from a tank to a welding gun. The gas is ignited at the tip of the gun and creates an intensely hot flame, with a temperature high enough to melt the metal. The aluminum parts are fused together when the wire is placed where the welding will take place and the torch is applied. Two pieces of aluminum weld together when the molten wire acts as a glue to fuse them together.
Welding aluminum is simple in theory, but the physical factors of the metal make it a challenge even for experienced welders. Aluminum has a high conductivity temperature and a low melting point. These two factors make it difficult to find the right welding torch temperature and required welding speed. Often, it takes a lot of practice with scrap metal before you really get the hang of this technique.
An overlooked element of successful aluminum welding is proper cleanliness. Even newly purchased aluminum that looks immaculate is soiled with aluminum oxide and will hinder the welding process by creating puddles and coiling the wire. Removing aluminum oxide is a simple process that requires a stainless steel brush, solvents, and etching solution. Pouring the liquid onto the metal and scraping gently with the brush will help ensure a smooth weld.
Safety is another overlooked part of welding aluminum. Most welders use a welding mask and gloves, knowing that dealing with sparks and hot metal can lead to severe burns. Long sleeves are another strong consideration. The TIG welder emits the highest amount of UV rays of any welding equipment and can cause severe burns when skin is not protected.
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