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Solutions For Aluminum Alloy Welding

There are many welding methods for aluminum alloys, and each method has its own unique applications. In addition to traditional fusion welding, resistance welding, gas welding methods and other welding methods (such as plasma arc welding, electron beam welding and vacuum diffusion welding) can also be used to easily weld aluminum alloys together.

Solutions For Aluminum Alloy Welding 1

The characteristics and applications of common welding methods for aluminum alloys are shown in Table 1. Select the welding method according to the grade of aluminum and aluminum alloys, welding parts' thickness, product structure and welding requirements.

Table 1 : Characteristics and applications of common welding methods for aluminum alloys

Welding methods

Characteristics

Applications

Gas welding

Low heat power, large deformation of welding parts, low productivity, easy to produce slag, cracks and other defects

Used for thin plates butt welding and repair welding

Manual electric arc welding

Poor quality joints

Used for repair welding of cast aluminum parts

Tungsten arc welding

Dense weld metal, high joint strength, good plasticity, can obtain high quality joints

Wide range of applications, weldable plate thickness 120.

Tungsten Pulsed Arc Welding

Stable welding process, precisely adjustable heat input, small deformation of welding parts, high quality joints

Used for thin plates,all-position welding,assembly welding, and high-strength aluminum alloys such as forged aluminum and hard aluminum that are highly sensitive to heat.

Fusion arc welding

High arc power, fast welding speed

Used for welding thick parts, weldable thickness is less than 50mm.

Melting pulsed arc welding

Small deformation of welding parts, good resistance to porosity and cracking, wide adjustment of process parameters

Used for thin plate or all-position welding, used for welding parts with thickness of 212.

Plasma arc welding

Heat concentration, fast welding speed, welding deformation and stress is small, more complex process

For butt welding where the requirements are higher than for TIG welding

Vacuum Electron Beam Welding

Large  melt depth, samall heat-affected zone,small welding deformation,good mechanical properties of joints

For welding smaller size welding parts

Laser welding

Small welding deformation, high productivity

For welding parts requiring precision welding

 

 (1) Gas welding

The heat power of the oxygen-acetylene gas welding flame is low, resulting in more dispersed heat. This leads to large deformation of welding parts and low productivity. When welding thicker aluminum parts with gas welding, preheating is required. The weld metal after welding is not only coarse-grained and has loose tissue, but it is also prone to produce aluminum oxide inclusions, pores, and cracks. This process is only suitable for welding aluminum structure parts and castings with a thickness range of 0.5 to 10 mm.

(2) Tungsten argon arc welding

This process uses argon gas for protection during welding, the heat is more concentrated, resulting in stable arc combustion and dense weld metal, the welded joints have high strength and plasticity, making it widely used in the industry. Tungsten argon arc welding is a relatively complete welding process for aluminum alloys. However, the equipment required for this method is more complex and cannot be operated in outdoor open-air conditions.

(3) Fusion arc welding

Automatic and semi-automatic fusion arc welding has a large arc power, concentrated heat, a small heat-affected zone, and productivity that can be increased 2 to 3 times compared to manual tungsten argon arc welding. It can weld pure aluminum and aluminum alloy plates with a thickness below 50mm. For example, the welding thickness of a 30 mm aluminum plate doesn’t require preheating, and only welding positive and negative two layers can result in a smooth surface and excellent quality of the weld. Semi-automatic fusion arc welding is suitable for positioning welds, intermittent short welds and structural shape irregularities. Semi-automatic fusion arc welding torch can provide convenient and flexible welding, but semi-automatic welding wire diameter is thinner, and the weld porosity sensitivity is larger.

(4) Pulsed Arc Welding

a. Tungsten pulse arc welding: This process can significantly improve the stability of the small current welding process, it is easy to adjust various process parameters to control the arc power and weld shaping. There is a small deformation of welding parts and a small heat-affected zone, making it especially suitable for thin plates,all-position welding, assembly welding, and high-strength aluminum alloys such as forged aluminum and hard aluminum that are highly sensitive to heat.

b. Melting pulsed arc welding: The average welding current is small, and the parameter adjustment range is large. There is small deformation of the welding parts and heat-affected zone, high productivity, good porosity and cracking. It is suitable for thicknesses of 2 -10 mm aluminum alloy plates for all-position welding.

(5) Resistance spot and seam welding

It can be used to weld thin aluminum alloy plates with a thickness below 4mm. For products with high quality requirements, DC shock spot welding and seam welding can be used. Welding requires the use of more complex equipment, welding current, and high productivity, especially for mass production of parts and components.

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HERON is a metal connection equipment manufacturer, a high-tech enterprise based on welding technology and integrating R&D and manufacturing.

CONTACT US

Contact Person: Christina Liu
Tel: 86 20 87813325 / 86 20 87819588 / 86 20 87815075

Fax: 86 20 87813346

Email: info@heronwelder.com

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HERON is a metal connection equipment manufacturer, a high-tech enterprise based on welding technology and integrating R&D and manufacturing of automated production lines.
HERON, make joining simple
CONTACT US

Contact Person: Christina Liu
Tel: 86 20 87813325 / 86 20 87819588 / 86 20 87815075

Fax: 86 20 87813346

Email: info@heronwelder.com

Address: No.63 Xin Yi Road, Guangzhou, Guangdong China 510990

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