Aluminum welding for stable connections

Challenge of aluminum welding

Alongside steel, aluminum is the most widely used construction material. Its biggest advantage is that it is just as strong but only around half as heavy. The use of aluminum is therefore preferred for lightweight constructions.

Interesting facts about aluminum

Pure aluminum (Al99.5) is not very strong. However, it is used as the basis for alloys with a strength that matches up to steel.

Welding aluminum is particularly difficult because the material is surrounded by an oxide layer. This only melts at around 3659 degrees Fahrenheit, while aluminum itself melts at around 1202 degrees depending on the alloy. If the oxide layer were to be melted in the conventional manner then the aluminum would run away, and welding would be impossible. It is therefore necessary to destroy or displace the oxide.

What alloys of aluminum are there?

The properties of pure aluminum can be changed using alloys. For example, adding magnesium considerably increases the strength of the material.

The most important components of aluminum alloys and their properties are:

Magnesium (Mg)
0.3–7% higher strength, finer grain size
Manganese (Mn)
0.3–1.2% better corrosion resistance, higher strength
Copper (Cu)
roughly 5% higher strength, lower corrosion resistance, important for hardening capacity
Silicon (Si)
12% for casting, reduces the melting point to 1070,6°F, however with coarse grains

Advantages

Very light but strong
Corrosion resistant
Temperature resistant
Not sensitive to UV radiation

Disadvantages

Expensive parent material
Difficult to weld

Welding process for aluminum

MIG/MAG welding

Ideal if a higher deposition rate is required—for example when welding filler beads. More information about MIG/MAG welding

TIG welding

For visually perfect seams and strong connections. More information about TIG welding

Professional power sources for aluminum welding

TPS 320i

MIG/MAG welding system
Integrated data documentation
Intuitive touch display

Find out more about TPS 320i

TransSteel 2200

Multiprocess system: MIG/MAG, TIG, manual metal arc welding
Portable and light for mobile use
Intuitive operation and easy menu navigation

Find out more about TransSteel 2200

iWave 230i

Alternating current TIG welding system from the new generation
Intuitive menu navigation
Can be expanded with optional function package

Find out more about iWave 230i

TPS 320i

MIG/MAG welding system
Integrated data documentation
Intuitive touch display

Find out more about TPS 320i

TransSteel 2200

Multiprocess system: MIG/MAG, TIG, manual metal arc welding
Portable and light for mobile use
Intuitive operation and easy menu navigation

Find out more about TransSteel 2200

iWave 230i

Alternating current TIG welding system from the new generation
Intuitive menu navigation
Can be expanded with optional function package

Find out more about iWave 230i

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Perfect Welding

Aluminum Welding Stable connections, lightweight

Challenge of aluminum welding