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How To Weld Aluminum Alloy Welding Rod

Sep 11, 2020

1.What is the Aluminum Alloy Welding Rod

       The Aluminum alloy welding rod refers to the welding process of aluminum alloy materials. Aluminum alloy has high strength and light weight. The main welding processes are manual TIG welding (non MIG welding), automatic TIG welding and MIG welding (MIG welding). The base metal, welding wire, shielding gas and welding equipment are need

2.    What is the Main welding methods of Aluminum Alloy Welding rod

1. Argon tungsten arc welding: 

TIG welding is mainly used for aluminum alloy, which is a better welding method. However, the equipment of TIG welding is more complicated, and it is not suitable to operate in the open air.

2. Resistance spot welding and seam welding

This welding method can be used to weld aluminum alloy sheet with thickness less than 5mm. However, the equipment used in welding is relatively complex, with high welding current and high productivity, which is especially suitable for large-scale production of parts and components.

3. Pulsed argon arc welding

Pulsed argon arc welding (TIG) can improve the stability of welding process, and the parameters can be adjusted to control the arc power and weld formation. The welding piece has small deformation and small heat affected zone, which is especially suitable for thin plate, all position welding and welding of forged aluminum, hard aluminum and super hard aluminum with strong heat sensitivity.

4. Friction stirs welding

Friction stir welding (FSW) has been widely used in light metal structures, such as aluminum alloy and magnesium alloy. The main feature of this method is that the welding temperature is lower than the melting point of the material, which can avoid the defects such as cracks and pores caused by fusion welding.

3.    What is the usage environment of Aluminum Alloy Welding rod

1.    Requirements for the storage environment and auxiliary materials used in aluminum alloy welding production

(1) Requirements for production and storage temperature and humidity

The production and storage environment of aluminum alloy must be dustproof, waterproof and dry. The ambient temperature is usually controlled above 5 , and the humidity is controlled below 70%. Try to ensure that the humidity of the welding environment is not too high. Too high humidity will significantly increase the probability of pores in the weld, which will affect the quality of welding. The violent flow of air will cause insufficient gas protection, resulting in welding pores. A windshield can be installed to avoid the influence of indoor wind through [2].

(2) Requirements for the use of welding wire and air hose

Attention should be paid to the use of welding consumables: aluminum welding wire should be stored separately from steel welding consumables, and the service life should not exceed 1a. After welding, take out the welding wire from the welding machine for sealing treatment to prevent contamination. Air supply hoses of different materials have different resistance to moisture ingress, especially when the air supply pressure is high, the effect of the air supply hose is more obvious. The air supply hose is best to use Teflon hose (Teflon).

4.    How to select the tools of Aluminum Alloy Welding rod

For aluminum alloy welding, it is better to use point contact tooling to reduce the contact area between tooling and workpiece. If the tooling is in surface contact with the workpiece, it will quickly take away the heat of the workpiece and accelerate the solidification of the molten pool, which is not conducive to the elimination of weld pores. The pressure of the tooling hydraulic system is best controlled at 99.5MPa.

Too little pressure cannot achieve the purpose of anti-deformation, but too much pressure will increase the restraint of the aluminum alloy structure. Due to the large linear expansion coefficient of aluminum alloy and poor high-temperature plasticity, large thermal stress is likely to occur during welding, which may cause cracks in the aluminum alloy structure.

5.    How to select the types of Aluminum Alloy Welding rod

1. Selection of welding wire

For 6005A, 6082, 5083 base metals, the selected welding wire grade is 5087/AlMg4.5MnZr, 5087 welding wire not only has good crack resistance, excellent pore resistance, and strength performance. For the selection of welding wire specifications, the welding wire with large diameter is preferred. The same welding filling amount is the same weight of welding wire. The surface area of the large-sized welding wire and the smaller-sized welding wire is much smaller. Therefore, the surface pollution of the large-sized welding wire and the smaller-sized welding wire is less, that is, the oxidation area is smaller, and the welding quality is easier to meet the requirements. . In addition, the wire feeding process of large diameter welding wire is easier to operate. Generally, 1.2mm diameter welding wire is used for base materials with a thickness of less than 8mm, and 1.6mm diameter welding wires are used for base materials with a thickness of 8mm and above. The automatic welding machine uses a 1.6mm diameter welding wire.

2. Selection of protective gas

Ar100% is characterized by stable arc and convenient arc ignition. Generally, Ar100% is used for welding of base materials with plate thickness below 8mm. For the base metal of 8mm and above and the welds with high pore requirements, Ar70%+He30% is used for welding. The characteristics of helium gas are: 9 times the thermal conductivity of argon gas, faster welding speed, reduced porosity, and increased penetration. When welding thick plates, the penetration depth of Ar100% and Ar70% + He30%. The gas flow rate is not as large as possible. Excessive flow will cause turbulence, resulting in insufficient protection of the molten pool. Air reacts with the deposited metal, which will change the weld structure, reduce performance, and increase the tendency of welding pores.