How to cook aluminum with a grinder

How can you weld aluminum at home?

Modern industrial production is developing by leaps and bounds, and over time, many different ways of connecting metal parts have appeared. However, they are all conditionally divided into two categories:

1. Detachable (that is, they can be dismantled without violating the integrity of the entire structure).
2. One-piece (during dismantling the structure is destroyed).

The last category also includes connections using welding seams. It is often used with steel parts, but in some cases there is a need to weld aluminum products.

What does a beginner need to know?

Welding aluminum is characterized by one significant feature: upon contact with oxygen, a kind of oxide film appears on its surface, which can only be removed by chemical action. This explains the use of substances designed to prevent its formation and allow direct contact with the metal surface. All such products are called fluxes.

In addition to fluxes, during the welding process at home it is necessary to use a tool used to remove dirt. We are talking about special steel brushes.

Basic welding methods

Welding aluminum at home can be carried out using two different methods.

1. The area of ​​the future joint is heated with a gas burner.
2. Using electrical voltage, where the stability of the spark is controlled by a closed electrical circuit.

Gas welding of aluminum

Step one.

First, you should take care of all the necessary tools. In addition to all of the above, gas welding also uses a small-sized aluminum rod , which allows not only to obtain a high-quality seam, but also a reliable connection.

I would like to devote a few words to these rods.

Firstly , there are several modifications of it, which are chosen depending on the percentage of aluminum in the metal and its thickness. Thus, the rods can be about 3% manganese or more, with a diameter of 2 to 4 millimeters.

Secondly , such rods are sold by weight: if necessary, you can purchase one or five kilograms in a compact plastic cartridge.

Don’t forget about the gas burner itself—you won’t be able to cook anything without it.

Step two.

After we have carefully prepared for work, we can begin to clean the surface of the part at the places of future joints. This is where a steel brush comes in handy.

Step three.

After cleaning, the contact areas (and the surface closest to them) should be treated with flux. This will prevent the appearance of an oxide film and give us access directly to the aluminum itself.

We heat the gas burner to the required temperature and use it to heat the seams. At the same time, we apply an additional rod, which, under the influence of fire, melts and mixes with the main mixture, connecting them at the same time.

Electric welding

This kind of aluminum welding at home will require you to have extraordinary skills and craftsmanship.

After all, here it is necessary not only to optimally choose the diameter of the electrode used (remember, it is this that closes the contact at the joint and heats the metal to a temperature as close as possible to the melting point), but also the necessary mode of operation of the welding device. Read more about how to properly cook with electric welding

Electric welding is often with metal whose thickness does not exceed four millimeters. In addition, it has a number of disadvantages:

1. The quality of the seam leaves much to be desired.
2. During operation, metal splashes.
3. Poorly separated slag, which can subsequently cause rust.

Step one.

Preparing for work. We collect all the necessary tools (which were described earlier), prepare the welding machine and select electrodes. It is desirable that these are electrodes coated with aluminum - they melt several times faster than steel ones, hence the higher operating speed.

Step two.

We activate the welding machine. It should be noted that for aluminum of medium thickness a temperature from 250°C to 300°C , and for thick, massive parts - about 400°C.

Step three.

When welding, it is recommended to cool it slowly after heating the aluminum. This will prevent the occurrence of crystallization cracks, and also allows you to obtain a sufficient degree of penetration with minimal energy consumption. If we weld large parts, we use local heating.

We weld the necessary parts. Under no circumstances should the electrode vibrate transversely!

Step five.

After the welding is completed, we remove the formed slag from the seam, wash the seam and re-treat it with a steel brush. Otherwise, the structure will rust.

Some recommendations

Source: https://varimtutru.com/chem-mozhno-zavarit-alyuminiy-v-domashnih-usloviyah/

How to weld aluminum: description of electrode welding technology

Currently, aluminum is used in a wide variety of fields. This thin and flexible material is often found in vehicle parts, including engine blocks, transmissions and body parts. It is also used to create stainless steel containers for household and industrial needs and many other important everyday items.

If a crack or problematic hole forms in such a structure, it is better to close it using a special apparatus in an argon environment. However, not every average person has such a unit at their disposal, so they have to look for more affordable solutions. One of them is aluminum electrode welding .

To successfully carry out such an activity, it is necessary to acquire a certain set of skills and purchase the appropriate equipment and supplies. The principle and technology of such welding are quite simple, so with the right approach you can learn them in a short time.

Features of working with aluminum

Electric arcs are used to connect many types of iron. This technique ensures a sufficiently high combustion temperature, resulting in high-quality penetration of plates of different thicknesses, creating reliable and hermetically sealed protection. However, welding aluminum using an inverter is considered the most difficult due to certain specific characteristics.

The first difficulty lies in the hygroscopic properties of the material, which can accumulate ambient moisture. And although this cannot be noticed in a naturally cooled state, problems will certainly arise when welding begins. When the arc is ignited and the metal is heated to elevated temperatures, moisture particles begin to evaporate from the surface and inevitably penetrate into the welding zone. The result is excessive spatter and interference that prevents a normal seam.

To prevent this phenomenon, it is enough to preheat the structure at a temperature of 150−190 degrees Celsius. In this case, you can notice intense release of moisture on the surface .

The next difficulty is the presence of an oxide film that covers all products. Its purpose is to protect the structure from the aggressive effects of an acidic environment. However, this makes processing with an inverter significantly more difficult.

The main problem is associated with the large difference in melting temperatures. It is known that aluminum itself begins to melt at 500 degrees Celsius, and its oxide at 2000 degrees.

To eliminate such a difference, it is enough to clean the welding site with an iron brush to ensure the required access to the metal .

Interaction with the environment ensures the correct formation of pores in the joint structure, which significantly worsens the tightness. To protect the weld pool, argon or a gas cloud is used during inverter welding.

It is no secret that pure aluminum is practically not used for the manufacture of parts, so the fillers and additional elements included in its composition can become a problem. For example, grades Al2 and Al2 contain silumin from 4 to 13%, so they are usually called limitedly weldable. Similar indicators are typical for models AM r 1 and Amr 6, where manganese is added in a proportion of 2−6%.

Stages of welding activities

Understanding the key intricacies of aluminum welding is not as difficult as it might seem at first glance. Through numerous attempts and experiments, you can achieve successful results and learn such a skill by heart. So, step-by-step actions for high-quality joining of metal products consist of the following stages and features:

1. If the thickness of the plate being welded exceeds 5 millimeters, it is necessary to cut the edges. To do this, it is recommended to cut the edges at an angle of 45 degrees, although other values ​​are also allowed. It is no secret that the width of the weld seam depends on the size of the cutting angle. If the thickness of the plates exceeds 7 millimeters, then you will have to make a technical gap between each part of two millimeters. If the work object is represented by a crack, then it is widened using a cutting disc and a grinder. Otherwise, the seam will be superficial.
2. The prepared workpiece is thoroughly heated. A propane-oxygen flame is used to remove excess liquid. The role of the working tool is performed by a cutter or an ordinary can with a household torch. It is necessary to warm the surface to 150 degrees and make sure that the material is dry enough.
3. After thoroughly warming up, it is necessary to clean the oxide film. In this case, you can use a regular brush to clean the metal. It is important to remove the refractory layer at the beginning of the welding zone. The following actions are carried out using an electrode, the composition and temperature of which can corrode the oxide and re-weld.
4. Tacks are installed on the prepared product, which secure all parts to be welded. The root seam should be smooth and completely fill the gap. The angle relative to the parts being welded must be at least 90 degrees. This may seem unusual to inexperienced welders, or those who have had to work with carbon steels. However, in this way the molten metal will more accurately fall into the joint. After the surface cools, the slag falls off. Unfortunately, this action is carried out with great difficulty, so you cannot do without a sharp hammer.
5. The next layers of the seam are applied until the entire thickness is filled.

Preparatory actions

Regardless of the welding conditions - industrial or home, you need to properly prepare the edges of the workpiece . Such an action consists of the following processes:

1. The surface of the part that will be welded (as well as the surface of the filler material) is thoroughly cleaned of dirt, oil and grease. To degrease the surface, white spirit, acetone, aviation gasoline and many other solvents are used.
2. The preparatory stage also includes such actions as cutting the edges of welded parts, which is performed only when absolutely necessary. If you do not use coated electrodes when welding, then edge cutting is carried out when the thickness of the parts being joined exceeds 4 millimeters. If the thickness of the aluminum alloy exceeds 20 mm, then the use of electrodes is indispensable. If aluminum sheets up to 1.5 millimeters thick can be welded, then their ends are pre-flanged before joining.
3. As mentioned above, immediately before welding, the surface of the part must be completely cleaned of the oxide film. In this case, it is common practice to use a high-quality file or a bristle brush to clean the metal. In some cases, a thin layer of oxide film is also removed using special chemicals, such as caustic soda, gasoline and others. When treating with caustic soda, the workpiece must be thoroughly rinsed with running water .

Equipment and electrodes

Pay attention to the list of the most necessary tools and accessories . In most cases, the operation is carried out using a conventional inverter. This device has a convenient design, so it is easy to move or move around the workshop. The polarity is set in such a way that the “plus” is placed in the worker’s hands, and the “minus” affects the workpiece. In this case, you need to get a 220 V outlet.

When choosing electrodes, you should give preference to specialized models such as UTP 48 or similar analogues. They can have different diameters and be selected taking into account the thickness of the metal. The composition of consumable raw materials also has some hygroscopic properties, so it must be pre-dried to ensure a better connection .

According to experienced specialists, electric welding of such flexible metal without the use of argon is sometimes carried out as well as with argon welding. If someone dissuades you from such a decision, arguing that it is of poor quality of the final seam and poor weldability, do not believe it. Most likely, he approached the method incorrectly or never tried to weld aluminum using an electrode .

To avoid irreparable mistakes and unpredictable troubles, it is enough to follow a number of recommendations and rules:

1. The butt joint method is considered the most promising. Other types in the form of a T-weld or lap welded joint are impractical, since they increase the likelihood of slag flowing into the gaps, which will cause a corrosion reaction.
2. After welding operations, the seam is washed with water to clean the workpiece from slag.
3. Immediately before processing, the material must be properly prepared. To do this, remove the oxide film and prevent its appearance in the future.
4. When welding massive parts with a thickness of three millimeters or more, it is necessary to separate the edges at an angle of 60 degrees with a V-shape.
5. Primary heating of aluminum is carried out at 150−250 degrees Celsius.

Do not forget that technically pure aluminum can be welded much better than alloys containing magnesium or manganese . We are talking about duralumin or silumin. However, products made from pure material are practically not used, so some difficulties may arise during welding.

Reasons for deterioration of metal weldability

If you encounter any difficulties or unpleasant moments during the welding process, you need to take into account many unique properties of the metal :

1. The key difficulty of heat welding is the presence of an oxide film, which can only be melted under the influence of temperatures of 20440 degrees Celsius. Melting of the metal itself begins at a lower temperature - from 660 degrees.
2. Drops of the molten part appearing in the welded zone are very quickly covered with a refractory oxide film, which prevents the formation of a continuous seam. To protect the workpiece from this phenomenon, the welded area is protected from contact with ambient air using argon.
3. Molten aluminum is characterized by high fluidity, and this significantly complicates the further formation of the weld pool. For this reason, work is carried out using additional heat-dissipating pads.
4. Aluminum contains dissolved hydrogen, which is directed outward after the molten metal solidifies. As a result, this causes the appearance of pores and crystallization cracks in the seam. In addition, alloys of this metal are characterized by an increased concentration of silicon, which also causes cracks to appear as the product cools.
5. Aluminum has a decent linear expansion coefficient. Because of this, significant shrinkage of the metal may occur during solidification, which causes a number of serious deformations of the parts being connected.
6. Welding of pure aluminum and its alloys is carried out under the influence of high values ​​of welding current. Metal is characterized by high thermal conductivity. Also, when welding, it has become common to use currents with lower strength.
7. Welding parts made of this metal is considered difficult in cases where it is not possible to determine the exact grade of the alloy. In this case, you have to spend a long time and diligently choosing the appropriate welding mode and methods used.

Anyone can learn all the intricacies of welding aluminum with an electrode. All you need to do is be patient and willing to set aside a few hours of your time to study the relevant material and guidance. In this case, you will be able to perform many important operations at home, without seeking help from qualified employees .

Source: https://tokar.guru/svarka/tehnologiya-svarki-alyuminiya-elektrodom.html

Welding aluminum with carbon electrode

+——————+—————————-+——————+

¦ Thickness ¦ Diameter, mm ¦ Current strength, A ¦¦ metal, mm +————-+—————+ ¦¦ ¦ filler ¦ electrode ¦ ¦¦ ¦ wire ¦ ¦ ¦+—————— +————-+—————+——————+

¦2- 5           ¦1 — 6        ¦8            ¦120 — 200       ¦+——————+————-+—————+——————+

¦5- 10           ¦5- 7        ¦10           ¦220 — 280       ¦+——————+————-+—————+——————+

¦10- 15          ¦7 -10       ¦12           ¦280 — 350       ¦+——————+————-+—————+——————+

¦15 and more ¦10 - 12 ¦15 ¦350 - 450 ¦+——————+————-+—————+——————+

Welding of aluminum with a metal electrode is performed with direct current of reverse polarity. Welding is carried out in the modes given in Table 64.

Table64

Welding modes of aluminum and its alloys with a metal electrode

+—————————+———————+—————-+

¦ Metal thickness, mm ¦ Electrode diameter, ¦ Current strength, A ¦¦ ¦ mm ¦ ¦+—————————+———————+—————-+

¦1- 3                    ¦3                  ¦8 — 100        ¦+—————————+———————+—————-+

¦3- 5                    ¦4                  ¦150 — 180      ¦+—————————+———————+—————-+

¦5- 8                    ¦5                  ¦250 — 320      ¦+—————————+———————+—————-+

¦8- 10                   ¦6                  ¦300 — 350      ¦+—————————+———————+—————-+

¦10- 15                  ¦8                  ¦350 — 400      ¦+—————————+———————+—————-+

¦15 and more ¦10 ¦400 – 450 ¦+—————————+———————+—————-+

Gas welding of aluminum and its alloys is ineffective and is performed using the fluxes given in Table 60.

The flame power is taken depending on the thickness of the metal being welded according to table 65.

Table65

Dependence of acetylene consumption on metal thickness

+——————-+——-+——+——+——-+——-+——-+

¦Metal thickness, mm¦0.5 - ¦1.0 ¦1.5 ¦1.6- ¦3.1 - ¦5.1 - ¦¦ ¦0.8 ¦ ¦ ¦3.0 ¦5.0 ¦10 ,0 ¦+——————-+——-+——+——+——-+——-+——-+

¦Acetylene consumption, ¦50 ¦75 ¦50 — ¦100 — ¦200 — ¦400 — ¦¦cub.dm/h ¦ ¦ ¦100 ¦200 ¦400 ¦700 ¦+——————-+——-+ ——+——+——-+——-+——-+

In the process of welding aluminum and its alloys, the flame must be strictly normal. The diameter of the filler wire depends on the thickness of the metal being welded and is taken as given in Table 66.

Table66

Source: https://steelfactoryrus.com/svarka-alyuminiya-ugolnym-elektrodom/

How to weld aluminum using electric welding

10.04.2019

Aluminum structures and parts sometimes need to be urgently repaired. Having welding skills, many weld aluminum themselves using electric welding. It is impossible to make a quality seam at home. But welding aluminum with an electrode is often used as an emergency measure. When working with light metal, you need to take into account the characteristics of the alloys. Manganese increases oxidizing capacity, magnesium improves weldability, silicon reduces the melting point.

Features of aluminum electrode welding

It is impossible to weld aluminum with an electrode without a protective atmosphere. The hot metal is quickly saturated with hydrogen, the seam becomes porous, the melt splashes heavily, and the seam turns out uneven. To reduce spattering, the metal is welded using a current of reverse polarity, the negative terminal is connected to the part, and the positive terminal is connected to the holder. The workpieces are preheated to +150 – +190°C to eliminate water accumulating in the pores of the oxide layer.

Difficulties arise due to the oxide film; it melts at +2037°C, aluminum - at +660°C. Before welding, the oxide layer is cleaned to a shine. Surface cleanliness affects the quality of the connection.

The alloys have good thermal conductivity, it heats up quickly, cools down, shrinks greatly, internal stresses and cracks arise. When welding metal, heat-dissipating pads are used. They maintain the required temperature.

Light metal is cooked at home at high currents. Electrodes are chosen special ones intended for welding.

Selecting a welding machine and electrodes

Aluminum is a difficult-to-weld metal. The operating current should be 1.5 times higher than for steel. The welding machine must generate a direct current of up to 250–300 amperes. A household welding machine powered by a 220 V network is suitable for the job. You can choose rectifiers, transformers or generators, but it is better to opt for an inverter, its advantages:

• high efficiency, up to 95%;
• low inductive losses;
• reduction of current consumption due to automatic shutdown;
• the device calmly tolerates voltage drops in the network;
• a stable arc is maintained, it is enough to touch the workpiece;
• there are additional functions;
• Small dimensions, you can carry it anywhere.

Source: https://svarkaprosto.ru/tehnologii/svarka-alyuminiya-elektrodom

How to weld aluminum: description of electrode welding technology - Machine

page » About welding » How to weld correctly » Welding aluminum » Welding aluminum with electrodes

As a rule, special equipment and special technologies are most often used for welding aluminum structures and parts. Welding using manual arc welding is quite difficult . But sometimes it is necessary, and we will help you figure out how to weld aluminum structures with electrodes.

When working with aluminum, the following types of welding are mainly applicable:

• MMA (manual arc welding of aluminum (see electrodes for aluminum));
• MIG (semi-automatic aluminum welding);
• TIG (welding of aluminum in an argon atmosphere using filler wire).

We will not touch upon the topic of agro-arc welding or the use of tungsten electrodes. Below we will talk about carrying out welding work with simple manual coated arc welding electrodes .

Aluminum electrode welding (MMA)

MMA (Manual Metal Arc) - manual arc welding with coated electrodes. This method is far from the most effective when working with aluminum products. Disadvantages of manual arc welding:

• it is difficult to make an even seam;
• the seam may be porous and not very durable;
• when the electrode melts, strong spattering is observed;
• It is difficult to clean the seam from slag.

And yet, despite the listed disadvantages, there are situations when manual arc welding cannot be done without . MMA welding can be used to connect aluminum structures that do not bear heavy loads . The minimum metal thickness must be no less than the thickness of the electrode (4 mm).

Manual arc welding with coated electrodes is useful at home when it is not possible to use bulky and expensive equipment .

Welding with inverter

Of course, there are other techniques that can be used in manual arc welding: rectifiers, transformers or generators. However, an inverter is the most profitable option due to the following advantages:

• High efficiency - up to 95% and above. The high-frequency pulse semiconductor converter completely eliminates inductive losses.
• Efficient energy consumption . The inverter automatically turns off when operation stops.
• Protection from unstable electrical network . The inverter produces the required voltage regardless of network sags. The pulse converter automatically adjusts to the input voltage and provides the required output parameters.
• Precise adjustment of welding current . The current required for specific welding jobs directly depends on the thickness of the electrodes used. The inverter control knob allows you to set the desired value before starting work.
• Quick arc ignition . It is quite easy to hit the part with an electrode. The inverter ensures stable combustion of the welding arc.
• Convenient to use at home . Inverters, as a rule, have compact dimensions. For comparison, a welding transformer with a power of 8 kW weighs more than 40 kg, while an inverter of the same power weighs less than 5 kg.

Features of the technology

Let's look at the features of aluminum electrode welding technology. Manual arc welding of aluminum is not the most convenient process, so it is important to know and take into account some features of welding.

• Selection of electrodes . First of all, you need to select the appropriate type of electrodes. The fact is that some brands have a coating intended only for working with aluminum alloys. Others are used exclusively for welding pure aluminum. Therefore, this parameter should be taken into account. Electrode manufacturers indicate the purpose of a specific brand, so you can easily choose the right one.
• Surface cleanliness . When welding with electrodes, preparation of the surface of the structure is of great importance. It should be well processed so that the seam is smooth and durable.
• Current _ Aluminum welding is carried out using direct current of reverse polarity. This is due to the fact that an oxide film forms on the surface of this metal. And with reverse polarity, the film is destroyed using cathode sputtering.

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Chemical properties of aluminum

Aluminum is characterized by high solubility of hydrogen in liquid form with low solubility at the crystallization point. This directly affects the quality of welding work. If even a small amount of hydrogen dissolves in the weld metal, the weld may become porous , as the hydrogen will tend to escape.

Another important chemical property of aluminum is oxidation . The combination with oxygen creates aluminum oxide, which forms a kind of film on the surface of the metal.

On the one hand, the oxide film reliably protects the metal from corrosion. On the other hand, it becomes an obstacle to welding work . Despite the fact that aluminum melts already at 660.

3°C, melting temperature of the oxide film - 2037°C.

Mechanical properties of aluminum

The strength, elasticity and elongation of the weld depend on the type of alloy from which the parts are made, as well as on the composition of the electrode. The strength of the welded joint will be quite weak in cold-hardened alloys. To achieve good weld strength in heat-resistant alloys, longer heat treatment times and slow cooling are required.

IMPORTANT! Aluminum has good thermal conductivity, so it is recommended to use heat-dissipating pads when carrying out welding work. This will help preserve the remaining parts of the workpieces from shrinkage and deformation.

To improve the quality of the weld, the following alloying additives can be used in aluminum electrodes:

• Manganese (Mn) - increases corrosion resistance.
• Silicon (Si) - reduces the melting of aluminum, improves fluidity and weldability.
• Magnesium (Mg) - gives the metal excellent weldability and good strength. When combined with silicon, it forms a heat-resistant alloy.

Electrodes OK AlMn1 (96.20) containing manganese

Which electrodes are better

A few words about which electrodes are best for welding with aluminum electrodes. For manual arc welding of aluminum structures, consumables from the manufacturer SpetsElectrod of the Ozana-2 brand are often used. Among the advantages of electrodes of this brand:

• ensure stable arc burning;
• the seam is well formed in any position (including vertical);
• slag formations on the working surface are easily separated;
• the weld seam has good mechanical properties.

Electrodes from the Swedish manufacturer ESAB of the “OK” series are also widely used. Consumables with alkali-salt coating are optimally suited for welding structures made of technical aluminum, as well as aluminum alloys with manganese or magnesium.

You can read more about choosing electrodes for aluminum welding here.
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Difficulties of the process

Let's look at the complexities of the electrode welding process on aluminum. The difficulty of manual welding of aluminum structures is largely due to the properties of this metal. Below are examples of the main problems that may arise during the welding process.

1. High metal fluidity . Molten aluminum is difficult to control. With significant overheating, the behavior of the metal becomes somewhat unpredictable. The melt can destroy the layer of solid metal underneath and flow out through the crack. To solve this problem, it is recommended to use ceramic or refractory steel gaskets .
2. Oxidability of aluminum . The main problem of aluminum products. Combining with oxygen, metal molecules form a dense oxide film. It is stronger than the metal itself and melts only at very high temperatures. Another disadvantage is that the film is a dielectric, so it is difficult to ignite an arc. To solve this problem, you need to thoroughly clean the metal working surface before welding .
3. High coefficient of linear expansion . Aluminum is quite fragile and has low elasticity. When the metal is very hot, the welding zone puts pressure on the rest of the structure, which can cause cracks or deformation of flat surfaces. To avoid this, you need to control the welding temperature . It’s better to preheat the part to 200-250°C.
4. When the weld metal hardens, it can crystallize and hot cracks appear . Therefore, it is advisable to add a special filler material. This is especially necessary in cases where several seams are located at a short distance from each other.

Source: https://regionvtormet.ru/svarka/kak-svarit-alyuminij-opisanie-tehnologii-svarki-elektrodom.html

How to weld aluminum parts at home

Aluminum has many positive properties, thanks to which neither aircraft manufacturing, nor the manufacture of electrical equipment, nor construction can do without it.

At home, it is also often necessary to carry out operations with aluminum: for example, to make an aluminum water tank, connect aluminum parts to each other, repair the metal body of any equipment, weld a pipe, etc. This metal is quite light, flammable, and has a high degree of electrical and thermal conductivity.

However, welding aluminum at home is a difficult task that requires preparation. From this article you will learn how to weld aluminum to aluminum at home and end up with a strong, high-quality connection.

Aluminum welding at work and at home

In industry, aluminum is welded using argon. A powerful jet of shielding gas prevents the metal from oxidizing during welding and protects the seam from the formation of pores. Cooking aluminum at home is problematic: not every novice welder has experience in argon welding. You may encounter the following problems:

1. Burn through material. When planning to weld aluminum with an inverter, remember that the metal is covered with a refractory oxide film. To destroy it, you will need to increase the temperature to 1400 -1450 degrees Celsius. It will be quite difficult not to burn through the aluminum part itself, because its melting point is much lower - 660 degrees Celsius.
2. Weld defects: pores, crystallization cracks. Their occurrence is due to the presence of elements such as silicon and hydrogen in aluminum. If the technology is incorrectly selected, a defective seam can be visually distinguished from a high-quality one as soon as the metal hardens.
3. Spreading of metal from the weld pool. Since the material is very fluid, you need to weld aluminum with an inverter using heat-dissipating pads.
4. The appearance of a characteristic crater on the seam, which forms in aluminum upon completion of the work. Its elimination requires special skills.
5. Deformation of welded surfaces during solidification. This occurs due to shrinkage of the material. The least likelihood of modification of parts is guaranteed if you weld aluminum with a laser.

Preparing aluminum for welding

Before welding aluminum, the part is thoroughly cleaned with a wire brush to remove dirt, traces of varnish and old paint. Then the surfaces are degreased with a solvent. To ensure the integrity of the metal, it is treated with a penetrating solution.

The oxide film from the surface is etched off with a 5% alkali solution heated to 60-70 degrees Celsius. As a rule, a couple of minutes is enough, after which the parts are washed with hot and cold water.

Then they should be placed for 6-7 minutes in a 20% nitric acid solution, also heated to 60-70 degrees. Washing occurs first with cold, then with hot water, after which the part is dried. Surfaces should be welded no later than 2-3 hours after cleaning.

If you plan to weld with a conventional consumable electrode on aluminum, then the electrode must be processed according to the scheme described above.

The cutting of edges depends on what materials will be used for welding. When using coated electrodes, the ends are flanged if they are not thicker than 1.5 mm, and cut if they are thicker than 20 mm. If other electrodes are used, then cutting the edges is necessary when the thickness of the parts is more than 4 mm.

With the suture method, the metal surfaces must be tightly fitted to one another. In addition, their thickness should not exceed 4 mm. The point method assumes that the thickness of the parts will be in the range of 0.04 - 6 mm with a maximum gap of 0.3 mm.

With proper preparation and a well-chosen mode, aluminum can be welded with any equipment: a welding inverter, a transformer, and a semi-automatic machine. Having decided how to weld aluminum, decide how exactly the process will proceed: with or without the use of shielding gas.

Argon welding of aluminum

Welding aluminum at home using argon can be carried out:

• Non-consumable electrodes.

Carrying out work with a non-consumable electrode on aluminum is most advisable if you need to get ceiling and vertical seams or weld a crack. However, welding can be done in all spatial positions. Since argon has more mass than air, when forming all seams except horizontal ones, this gas can be mixed with helium.

To calculate the optimal current strength, you need to multiply the number of millimeters of electrode diameter by 30-45. Approximately this number of amperes will be needed to form a strong connection. If parts have a thickness of up to 6 mm, then electrodes with a thickness of up to 4 mm are suitable. If the thickness of the workpiece exceeds 6 mm, then you need electrodes with a diameter of 6 mm. When calculating the amount of argon, keep in mind that in 1 minute of continuous operation, from 6 to 16 liters of gas will be consumed.

When working with a tungsten electrode, it should be guided behind the filler wire. By choosing the maximum speed, you can avoid seam defects.

• Filler wire. Semi-automatic electric welding is necessary if the thickness of the part is 3 mm or more. To weld with an inverter in a protective gas environment, select wire with a thickness of 1.2 - 1.6 mm. The closer its melting temperature is to the melting temperature of the part, the easier the welding will be.

When working with such a device, the wire is fed automatically, but the torch must be moved manually in the direction from right to left. The burner must be equipped with a Teflon guide and have a length of no more than 3 m. The distance from the nozzle to the aluminum surface is approximately 10-15 mm, the deviation of the burner from the vertical is 10-20 degrees. This is enough for good penetration, and gas consumption is quite economical.

How to weld aluminum semi-automatically can be found here.

Welding without argon

Many owners are interested in how to weld aluminum without argon. This requires special consumables - for example, Nobitec 412 electrodes or TBW Harasil NC12 rod. Prepare a large number of electrodes in advance, as they are consumed 3 times faster than what happens when welding steel products.

It is advisable to preheat the aluminum to a temperature of 150-200 degrees Celsius. Welding should be done with a short arc at a current of 70-100 A. The electrode should be positioned at an angle of 90 degrees. After finishing the work, the scale is beaten off with a hammer, and the weld seam is cleaned with a brush.

This method is suitable for those who do not know how to weld with argon or do not have equipment for gas welding. In this case, the strength of the connection will be no worse than with argon welding. Despite the fact that specialized electrodes are quite expensive, the final cost of the connection is less than when welding with argon.

Useful tips

• Welding must be done with direct current with reverse polarity. Is it possible to weld aluminum with alternating current? It is possible, provided that the oscillator and ballast rheostat are used.
• Aluminum cooks best at a temperature of 18 – 22 degrees Celsius and humidity within 70%
• Surfaces must not be cleaned with sandpaper or abrasives.
• Aluminum alloys should be strengthened by cold hardening before electric welding. In industrial conditions, the aluminum coating can be up to 40% of its volume; in domestic conditions, a much thinner layer should be formed.
• To avoid hot cracks, the surfaces must be heated before welding.
• To learn how to weld without craters, first practice on unnecessary pieces of metal. Without turning off the arc, it is necessary to weld in the opposite direction. When welding the crater, form a kind of dome over it, and during cooling, a crack will not form in this place.
• The ejection speed of aluminum wire when using a semi-automatic machine should be 15-20% higher than that of analogues made of ferrous metals.
• Before welding aluminum with an electrode, do not forget to calcinate the consumable material, since it is very hygroscopic.
• If the arc breaks when welding with a consumable electrode, then the next seam should overlap the previous one by about 1 cm. Before continuing work, remove the slag crust from the electrode and crater.

Source: https://svarkaed.ru/svarka/svarka-metallov/kak-svarit-detali-iz-alyuminiya-doma.html

How to Cut Aluminum with a Grinder - Basis

An angle grinder is considered an extremely dangerous piece of equipment, so it is important to know in advance how to properly cut metal with an angle grinder in order to avoid injuries and do the task well. It is necessary to ensure compliance with safety measures when working and use personal protective equipment: use a respirator, wear protective gloves or mittens, goggles, etc.

Cutting equipment must be used strictly for its intended purpose; all work is carried out using special metal circles. It is strictly not recommended to remove the protective cover. How to work with an angle grinder correctly, watch the video:

How to properly cut a metal corner with a grinder

You cannot start cutting metal with a grinder without obtaining the appropriate knowledge and some skills. The most important danger is the possibility of the cutting wheel jamming in the cutting zone and its subsequent destruction. When carrying out work, the grinder must be held firmly with both hands. You need to carry out the cutting strictly from yourself. The depth of the cut is determined by the diameter of the disc.

Cutting a metal corner has some nuances:

1. It is easier to cut a large corner (more than 60 mm) together with a partner. In a workshop, the workpiece is clamped in a bench vice or fixed with clamps on a fixed base. The corner is laid on the surface of the supporting structure (table, box, etc.) so that the cut edge hangs down, and its other part lies completely on the surface of the support. An assistant should press the workpiece and slightly pull it away from you to prevent the disc from biting. Cutting begins from the edge, moving towards the rib.
2. Cutting corners with smaller dimensions (up to 60 mm) can be carried out without the help of outsiders. The material to be cut is laid out supported on both shelves (edge ​​up). The detachable part must be suspended and not touch the ground or floor. The remaining part is pressed down with the left foot (in the absence of rigid fixation) in order to hold the grinder with both hands. Cutting should begin from the edge, gradually going down and going deeper into the areas of the corner.

If the correct metal cutting technology is followed, the separated fragment will fall down under its own weight, thereby increasing the width of the cutting zone. The likelihood of disk jamming is minimized.

How to cut a pipe with a grinder

To cut pipes with a grinder, it is recommended to use cutting wheels with a thickness of no more than 1 mm, otherwise the cut will be more difficult, and there will also be too many sparks and flying hot particles.

The technology for carrying out the work is as follows:

1. The pipe is secured in a vice or secured in another way. In this case, the cut part should hang down. It is not allowed to place the workpiece between two supports and make a cut in the middle, as the cutting blade will jam (due to sagging pipe).
2. Markings are applied using a strip of paper and masking tape. The ends of the tape should meet as accurately as possible. Home craftsmen recommend lowering the pipe into the liquid at the required angle, and then marking the cut line along the dry and wet boundary.
3. The cut should be made from the top of the pipe, gradually lowering the angle grinder lower. The cutting disc should go along the very edge of the glued strip.

A large diameter pipe is cut a little differently, since the working part of the circle does not allow this to be done in one go. The wall is cut sector by sector, and the pipe is turned to the desired side.

How to cut aluminum with a grinder

To cut aluminum with a grinder, a different type of disc is used, since it is a soft metal and the cutting tool gets stuck in it. There are special cutting discs for aluminum and copper.

You should not try to make a cut in one pass, because cold hardening will form on the teeth of the cutting tool and it will become pinched in the material. The cut is performed carefully, without cutting through the metal all the way. You need to go through one place several times and avoid distortions.

The process is quite slow, and the quality of the cut will be low. When cutting thick workpieces, experts recommend dripping kerosene into the cutting area. It is better to work with aluminum with a hand router, which allows you to perform figured cutting and make holes.

Or you can do this:

Methods for cutting stainless steel

Stainless steel is an alloy steel that is quite difficult to process. This metal can be cut using 2 methods:

• thermal (metal melts under the influence of high temperatures);
• mechanical (cutting is carried out using a cutting tool by removing a layer of metal).

Thermal methods include:

1. Oxygen cutting (gas arc cutting). The metal melts under the influence of an electric arc. Oxygen supplied to the cutting zone promotes the combustion of metal and the removal of slag from the working area.
2. Electroerosive cutting. The cutting process involves destroying the surface of the workpiece under the influence of an electrical discharge.
3. Waterjet cutting. The metal is separated by a thin jet of abrasive mixture supplied under ultra-high pressure.
4. Laser cutting. The treatment is carried out with a thin laser beam.
5. Plasma cutting. A plasma jet acts as a cutting tool.

Machining of stainless steel is carried out using the following tools:

1. Metal scissors. They cope with sheets with a thickness of no more than 0.5-1 mm.
2. A circular saw. Cutting is carried out using a cutting abrasive wheel. This method can be used to cut thick parts.
3. Angle grinder. When cutting metal with a grinder, special thin stainless steel discs with a diameter of 125 mm are used. Non-specialized equipment can subsequently cause corrosion in the metal.

According to the cutting rules, the part must be securely fastened or rested against something, otherwise the workpiece may be pulled to the side and the cut will be damaged. It will be necessary to additionally process the cut edge if you cut without following the technology.

Cutting cast iron with a grinder

Cast iron is a rather fragile metal, but very durable, so it is recommended to use diamond-coated discs for cutting it. You can cut cast iron with simple metal discs, but they are much less durable. You can cut this material with a grinder only in a straight line.

Any attempt to make a figured cut can lead to jamming of the cutting wheel. As a result, under heavy loads, the abrasive element is destroyed and its parts flying out at high speed can seriously injure people nearby.

But it’s better to cut cast iron with a saw, as in the video:

You can use a grinder for cutting cast iron only when using a respirator (a lot of dust is generated), protective plastic glasses and gloves. Bakelite bonded cutting equipment is more suitable for this work. Ceramic bonded discs have a much smaller margin of safety.

Source: http://xn--80aabfqjhc8bhv.xn--p1ai/2019/06/06/kak-rezat-alyuminij-bolgarkoj/

Working with an angle grinder. How to cut aluminum with a grinder safely and quickly

Hello friends!
In this short note I want to share how you can cut aluminum with a grinder, a regular metal cutting wheel.

It would seem that what’s wrong with this, just take it and cut it!
This was not the case, especially when it comes to the need to cut a thick sheet of aluminum.

The fact is that aluminum is a soft metal and when cutting it with a grinder, the cutting wheel simply gets stuck in a piece of aluminum.

Why is it dangerous to cut aluminum with a grinder?

Cutting aluminum is not only difficult, but also unsafe!
Especially when using a high power grinder. Due to the viscosity of aluminum, the disc will get stuck and the tool will try to pull out of your hands.

And this will not happen immediately, but only when the cut reaches a certain depth. And this may come as a surprise to an inexperienced tool user. And in general, cutting with a disk stuck in the metal will not be easy.

A short story about how I had to cut an aluminum tank. And what came of it

One of my friends once had a job delivered to him and needed to saw an aluminum tank with a grinder. “It’s a piece of cake,” he thought—cutting aluminum, there’s nothing easier!

But his joy quickly disappeared when he got down to business.

The disk constantly got stuck, stuck in this metal.
The Bulgarian woman tried to jump out of her hands. Sawing was a pain; it went very slowly. Various abusive thoughts did not leave my head. )))

So what to do?
I got to work - I need to do it! So several hours of hard work passed. An old man passing by came to the rescue.

Seeing the torment, he began to try to give advice, but advice is sometimes difficult to accept, especially when his nerves are already at their limit. After all, the work, which seemed simple at first, was already pretty exhausting. Therefore, the first reaction to advice is the desire to send him to hell.

Nevertheless, the advice was given and in the end, as the friend said, he followed it. Imagine his surprise when after that things went much more fun.

What was the tip that helped you cut an aluminum tank easily?

The advice was as follows: The cut area needs to be lubricated. For example, used automobile oil is quite suitable for this purpose. A little processing, and the work begins to boil. The disc did not get stuck, the aluminum was cut with a bang. So, a simple trick from an experienced person helped save both nerves and strength. And perhaps health, since the angle grinder no longer gets stuck in the aluminum and tries to escape from your hands. You yourself understand the dangers of such a situation when working with this tool. Don't believe me?

Talk to surgeons, they will tell you.

Source: https://blogvp.ru/rabota-s-bolgarkoj-kak-rezat-alyuminij-bolgarkoj-bezopasno-i-bystro.html

How to weld aluminum at home with a torch?

Gas welding of aluminum is a widely used process in industrial applications, since aluminum has sought-after properties that are irreplaceable. In general, this process is considered to be correspondingly easy, but the metal has poor weldability properties, which makes it difficult to work with. Gas welding has several negative nuances, just like electric arc welding, which works with a welding transformer.

The main difficulties arise because there is a high chance of marriage. The expansion coefficient contributes to non-standard shrinkage, so it is worth monitoring both the welding modes and the thickness of the seam. Despite this, various microcracks and pores often arise, for the protection of which a special environment is used.

When welding aluminum using gas, two goals can be achieved at once, such as the temperature effect for melting, and the presence of a protective environment from harmful external factors.

Despite all this, we have to contend with the high fluidity properties of aluminum in the molten state. Gas welding helps to cope with such situations, but still it has its own abilities that should not be forgotten.

Argon welding is a very effective method, but it has no relationship with gas welding, since the main source here is an electric arc.

The main problem is removing the oxide film, which melts at a temperature of 2000 degrees, while the melting of aluminum begins at 700.

Advantages

• Gas welding of aluminum occurs at low speed, due to which the seam is formed qualitatively, the welding process takes much longer, unlike electric arc welding;
• The use of working gas to protect the weld pool from the ingress of various dirt, debris, and atmospheric air into it;
• Lack of use of electrodes with coating, which often contains hydrogen, which leads to the appearance of voltage in the metal;
• High level of welding quality, regardless of the welder’s experience;
• The ability to produce long continuous seams thanks to the use of filler material;
• It is generally easier to work with thin sheets;
• The use of a gas flame to heat and cool a part.

Flaws

• The use of gas, which requires enhanced safety precautions;
• Preparatory work for the work process and cleaning the workplace at the end take maximum time;
• Very expensive equipment compared to other types of welding
• Many devices are used.

Materials and tools

To carry out gas welding of aluminum, you will need the necessary equipment such as:

• Gas torch – gas is supplied through it for welding metal. There are many types of burners, but they all have two holes for gas supply and the ability to adjust parameters;

• Hoses – connected between the cylinder and the burner, special attention is required, since careless handling can lead to gas leakage due to cracks;

• Gas cylinder - here metal welding occurs mainly due to oxygen, there are also other gases such as acetylene and propane;

• Filler material is basically a wire that is supplied as the base material to form the weld. The types of wire are selected identically, in accordance with the qualities of the aluminum workpiece prepared for welding. If you gas weld aluminum up to 2mm thick, then the wire should be 1-1.5mm. When the thickness is up to 5mm, the wire should be 1.5-3mm, and more than 5mm, the wire should be 4mm and above.

Edge preparation

When gas welding aluminum it is very difficult to achieve the required penetration depth, so for a quality weld you need to bevel the edges. When the sheet thickness is less than 4mm, a bevel is not necessary, since the melting temperature of the burner is sufficient for adequate penetration.

In other cases, you need to make a bevel at an angle of 30 to 45 degrees; the slope increases if the thickness of the workpiece is different. You may need a lot of wire, but the quality of the seam will correspond to the work done. Finally, cleaning is done using a grinder, file, or other similar devices.

Step-by-step instruction

1. First, the workpiece needs to be thoroughly cleaned, fat removed, oxide film removed, and the edges beveled;

1. Next, you should spread the flux at the site of the future seam; it will increase the quality of weldability and prevent the appearance of an oxide film throughout the entire process;
2. It is necessary to heat the metal to the required temperature in order to avoid deformation from temperature changes and melting of the flux;
3. Afterwards, the main process of welding aluminum begins, where the wire is fed to the place where the weld bead is formed;
4. After completing the process, it is necessary to gradually lower the burner temperature, heating the metal, in order to avoid thermal stress;
5. After the part has cooled, you need to beat off the slag and clean it to the desired appearance.

Precautions

The process of gas welding of aluminum is life-threatening, like other types of welding using gas. Before starting the process, you need to make sure that the equipment is working properly by carefully examining the pressure gauge arrows. The cylinder should be placed within a radius of 5 meters from the welding site, since the torch flame can lead to an explosion. Handle the hoses carefully without damaging them, as gas may leak, which is also unsafe.

Source: https://rem-serv.com/kak-svarit-alyuminiy-v-domashnih-usloviyah-gorelkoy/

How to weld aluminum with an inverter - Technique Expert

In everyday life, products made of aluminum alloys are used, which occasionally require repair.

Is it possible to weld aluminum at home with an inverter? Yes, with the help of special electrodes, home craftsmen weld cracked or new products.

How to cook aluminum with an inverter without argon

First, special aluminum electrodes for electric arc welding are purchased. In this article, you can get acquainted with melting rods for joining aluminum alloys.

Aluminum welding with an inverter is performed using direct current of reverse polarity (+ on the electrode holder). For a running electrode with a diameter of 3.2 mm, the welding current on the machine is set to 80-100 A.

When connecting aluminum alloys, the holder with the electrode is placed at a right angle (90 degrees). The technology is performed with a short arc.

Please note: aluminum electrodes burn 3 times faster than usual, maintain the correct speed.

Thick metal more than 5 mm needs cutting edges. The V-shaped chamfer is cut with a bevel of 45-60 degrees.

Before welding, the workpieces are heated with a gas burner to 150-200 degrees for drying. And the electrodes are pierced in an oven according to the manufacturer’s instructions.

Without heating the aluminum products and drying the melting rods, the connection will not work.

As the workpiece heats up, you will see water appear on the surface and evaporate.

Further, the products are installed with a technological gap between them of 1-2.5 mm, depending on the thickness of the plates.

The oxide film is removed with a stainless steel brush (the use of abrasive tools is not recommended; abrasive particles will create joint defects).

After preparations, aluminum is welded with an inverter. After each pass, with thick metal, slag is removed with a hammer. Slag welding is not performed. Electrodes for aluminum alloys require cleaning of the tip as the process continues.

Aluminum alloys are divided into difficult and easy to weld. The table will help determine the weldability characteristics.

Welding inverter for aluminum welding

Inverter welding machines for aluminum welding are purchased in different brands and modifications. We looked at the use of electric arc devices. In practice, semi-automatic devices and attachments are also used for connections in a protective gas environment.

This article explains how to learn how to weld aluminum using argon gas.

Connecting wires by welding

How to weld aluminum wires with an inverter? The essence of the technology is simple:

• remove the insulation from the wires;
• make a twist;
• trim the twist (wires at the same level, length more than 30 mm);
• apply flux to remove the oxide film.

For connection, graphite or carbon electrodes and flux are purchased. Flux is a white powder, diluted with water until creamy and applied to the twists with a brush or by immersion. The flux removes the oxide film and prevents the carbon electrode from sticking.

The connection is made without an arc, by simply bringing the electrode to the twist for 1-2 seconds. On the inverter device, the current strength is set to 20 A.

The tip of the electrode must sometimes be cleaned of slag and scale. Before important work, it is better to practice on blanks.

After work, wipe the aluminum connections with solvent, apply varnish and insulate.

Source: https://kumselstroy.ru/drugie/kak-varit-alyuminij-invertorom.html

Instructions on how and what to cook aluminum: methods and technologies for beginners

Any metal can be welded using a welding machine, the main thing is to know how and with what to do it, as well as what additives to use for this. In this article we will look at how to properly cook aluminum even at home.

Problems

Aluminum is used almost everywhere, as its properties of heat and electrical conductivity show excellent values. Moreover, this material has a relatively low specific gravity.

The whole problem lies in the same properties, since too much overheating leads to a burn-through. But the current required is at least three times greater than when welding steel elements. The goal is to prevent overheating.

It is important to know how to weld aluminum with argon, because the preparatory work in this case is the most important. The thing is that when heated, a liquid bath is released, which prevents proper welding of the metal. In this case, argon is used, which prevents air mass from entering the welding processes.

Also, during work, other factors may arise that cannot be corrected by anything, but are only reduced due to the correctly selected mode.

How to cook aluminum at home

For household welding, it is better to use argon, since other approaches are prohibited due to the appearance of splashes and drops. To prevent the oxidation process, it is necessary to use tungsten electrodes, which protect the molten pool with the gas released.

You can also use one more method, for this it is important to know how to weld aluminum semi-automatically. This process involves feeding the welding wire through a specialized gun. The whole point is also the release of a special gas, which prevents the bath from contacting air and oxygen. In this case, it is necessary to use wire made of the same material that is welded together.

Surface preparation

We described above that there are several problems when welding aluminum. The first difficulty is solved by completely degreasing the material. To do this, you can place the metal in an alkaline environment for some time, that is, a bath, or use acetone or white spirit. It is advisable to keep the metal in such substances for no longer than five minutes, ideally three.

After this, it is necessary to process the edges where the welding seam will pass. To do this, you can use a metal brush either manually or attached to a drill or machine.

It is important not to press on the material during processing, as the oxidized film may get into the scratches from the brush. After processing, it is necessary to place the metal for a few more minutes in a degreasing solution.

The second difficulty, which involves the appearance of cracks, can also be excluded. To do this, you need to heat the metal under an open fire, where the temperature is about 100-150 degrees.

If metal of different thicknesses is used, then it is necessary to heat the thicker part first, since the opposite can lead to rapid cooling of the thinner part. Moreover, aluminum may contain droplets of moisture, which will cause a lot of splashes during welding, so heating will get rid of them too.

Main job

Electrode welding is allowed only for parts whose thickness is more than 0.4 cm, since thinner metal will certainly get burned through. The two basic rules for this type of work are to reverse the polarity and move the electrode as quickly as possible to avoid burn-through.

If for normal welding the grounding is compared with a minus, and the holder with a plus, then when welding aluminum it is necessary to change the order. As soon as the work is completed and the seam has dried, you need to beat off the slag, rinse the seam with warm water and go over the joint with a wire brush, and then you can also go over it with a grinder attachment.

This principle will reduce the presence of slag in the connection to a minimum. Watch a video or detailed photos on how to cook aluminum. This will help you visually understand the work ahead to get maximum quality and reliability.

Photo tips on how and what to cook aluminum

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Source: https://instrumentgid.ru/instrukciya-kak-i-chem-varit-alyuminij/

How to cook aluminum with an inverter without argon. Connection of aluminum wires

In everyday life, products made of aluminum alloys are used, which occasionally require repair.

Is it possible to weld aluminum at home with an inverter? Yes, with the help of special electrodes, home craftsmen weld cracked or new products.

Technique for welding aluminum electrodes with an inverter at home

High strength, low specific gravity and affordable price have made aluminum one of the most popular metals. It is used everywhere from the aerospace industry to the production of household utensils.

Repairing aluminum products and creating your own structures in a workshop at home is complicated by a number of features of the metal.

Welding aluminum with an electrode at home using an inverter is one way to overcome these difficulties, which does not require expensive equipment or highly qualified workers.

Features of work

The melting point of the metal is 660°C . When heated, the atoms react with oxygen, forming a layer of refractory aluminum oxide with a melting point above 2200°C. This layer prevents the full formation of the seam.

Aluminum has high thermal and electrical conductivity. In practice, this means that in order to heat the workpiece metal, especially with large thickness, it will be necessary to use large operating current values.

The metal and its alloys are also characterized by high fluidity, which makes it difficult to work in a number of welding positions.

To prevent contact of the melt and oxygen in the air, gas welding is used . Helium, argon or its mixtures are supplied to the working area, displacing air and creating a protective cloud. This method requires expensive equipment and a constant supply of gas. It is cost-effective for large volumes of work.

For limited work at home, manual DC electrode welding is suitable. For this purpose, coated electrodes are produced that are optimized for use with thermally conductive materials.

What do you need to know to make a quality seam?

To obtain strong and durable connections, you need to know and consider the following points:

• products made of aluminum alloys are always coated with a layer of refractory oxides;
• before starting welding, this layer should be removed by mechanical stripping or etching;
• the oxide layer is quickly restored in air, so the treatment must be carried out immediately before welding;
• the color of the aluminum billet practically does not change when heated, it will not be possible to monitor the temperature visually;
• When heated, the strength of the product decreases, this can lead to the appearance of microdefects during crystallization.

Taking these features into account allows you to avoid common mistakes when you need to weld aluminum blanks at home.

Is it possible with an inverter?

How to cook aluminum with an inverter and is it even possible to do it? This possibility exists. The use of coated electrodes makes it possible to work using conventional medium-power household-class inverters. Of course, such devices can only weld workpieces 3-4 mm thick. Thicker ones will require powerful semi-professional inverters.

Specifics

The inverter itself, used for welding aluminum workpieces, can be entry-level, household grade. Surface preparation, selection of welding materials and careful adherence to technology are of decisive importance .

Electrodes of the OZ series have excellent performance characteristics. But these qualities appear only at low humidity of the coating material. Therefore, before use, they must be calcined at a temperature of 120-140°C for 40 minutes. After calcination, the electrodes must be stored in an oven or in a special sealed case.

During work, you must be careful and careful. The high fluidity of the melt and its tendency to splash does not allow working in vertical and overhead positions . And in the lower welding position, it is recommended to use backing plates to prevent melt leakage.

To avoid thermal deformations during hardening, try to place the seams as far apart as possible.

What should the device be like?

There are no particularly specific conditions for the device . It must maintain a sufficient operating current for the selected workpiece thickness and electrode diameter. The operating voltage is set around 22-24 volts.

The device must support reverse polarity mode.

A large current reserve leads to an increase in size, weight and increased energy consumption.

If your plans for welding aluminum are large and such work is planned to be carried out constantly, then it is better to immediately purchase a device that supports the TIG mode, or welding with a non-fusible electrode in an argon or helium protective atmosphere. The electrode can be made of tungsten or graphite. This semi-automatic device allows you to cook with conventional fusible rod electrodes without gas supply.

Electrodes

The most popular electrodes used on aluminum for inverter welding are products from the following series:

1. OZA-1 . Used for welding pure aluminum workpieces. Before welding, it is necessary to remove the oxide layer and heat the surface to dry it.
2. OZA-2 . Used for surfacing with silicon-aluminum alloys. as well as for repairing defective castings.
3. OZANA-1 . For pure aluminum parts thicker than 10 mm. They need to be heated to 400°C.
4. OZANA-2 . Modification for welding aluminum alloys.
5. OKB96.20 . For work on aluminum alloys alloyed with Mn, Mg and Si. We can also use it on duralumin.

Covered welding technique

Welding of aluminum parts with an inverter is carried out using a current of reverse polarity, in the lower welding position . This is due to the high fluidity of the melt and the need to maintain a high speed of electrode movement

The electrode should be brought perpendicular to the seam line or with a slight tilt back. The trajectory of movement is straight, without transverse swings.

Operating modes for welding aluminum parts of different thicknesses.

The substances contained in the coating increase the resistance of the weld pool material to the passage of current, which complicates the re-ignition of the electric arc.

If the arc goes out, you should remove the slag layer from the crater and from the tip of the rod, and step back 1 cm . The remainder of the seam and the crater must be welded again to avoid porosity.

Upon completion of the seam, its surface is cleaned of slag and washed with water.

Rules for preparation and conduct

It is best to weld critical joints of aluminum workpieces using argon arc welding . The method using an inverter and rod fusible electrodes allows you to obtain quality sufficient for home repairs or construction. How to weld aluminum blanks at home using an inverter?

The strength and durability of the seam is largely determined by the quality and thoroughness of the preparatory work. They are designed to remove the layer of oxides with a high melting point that covers any part made of aluminum or its alloys upon contact with air.

The work is performed in the following sequence:

• clean the seam area and the heat-affected area using a wire brush or angle grinder;
• For cleaning, you can also use a chemical method by treating the surface with a reagent;
• calcinate the electrodes to remove moisture from the coating;
• if necessary, warm up the workpieces;
• the hand with the torch should move at a constant speed along a straight path, without lateral swings.

Upon completion of the seam, it should be cleaned of the slag layer, thoroughly rinsed with water and dried. This reduces the risk of corrosion occurring and spreading.

Conclusion

Welding aluminum with a coated electrode is an affordable and uncomplicated method that can be used at home. To do this, you need to use an inverter, high-quality electrodes and follow technology.

Source: https://svarka.guru/tehnika/opredelennih-metallov/invertorom-alyuminiya-elektrodami.html