How to weld aluminum correctly with a semi-automatic machine

How to weld aluminum with your own hands using a semi-automatic machine

Semi-automatic welding of aluminum is one of the most popular methods of welding metals on the surface of which an oxide film is formed. There are many other methods, but semi-automatic welding of aluminum in a protective gas environment is the most effective and affordable for home craftsmen.

To do the job correctly, you need to know not only welding technology, but also all the features of the metal. It is sometimes difficult for beginners to weld aluminum parts, and they ask many questions. In this article we will try to answer them, and also tell you what is needed for high-quality welding.

Main nuances and difficulties

The most important thing you should know before welding aluminum is the presence of a persistent oxide film on the surface of the metal. All the troubles come from her. The oxide film has refractory properties. To melt it, a higher temperature is required than to melt aluminum itself. It is for this reason that all beginners have uneven and fragile seams.

Also, welding aluminum semi-automatically in a protective gas environment or using any other available welding machine is complicated by the fact that aluminum has a relatively low melting point, while it conducts heat well. It is when welding aluminum that it is easiest to make a mistake with the machine settings and deform the metal due to the high current value.

This problem can be solved by the correct choice of welding mode. But the problem of the oxide film is solved by preliminary preparation of the metal. To do this, you need to thoroughly clean the metal surface with a wire brush. It’s better to use a hand grinder for this purpose.

https://www.youtube.com/watch?v=uNXJqHWAa6k

You can also find special products and fluxes in stores that impair the active properties of the film. We recommend using both methods at once. We also recommend slightly warming up the parts in the oven before welding. If you don’t have a stove, a gas burner will do, but you’ll spend twice as much time.

Selecting a semi-automatic machine for aluminum welding

Welding on aluminum is possible in many ways. Even manually, using melting electrodes. But this is a very labor-intensive process, and the quality of the seam will be unsatisfactory. We recommend using a pulse welding machine in your work. Namely, semi-automatic machines for TIG welding.

It is semi-automatic TIG welding that allows you to get the job done quickly and efficiently if you have to work at home. You can buy a simple inverter (MIG) for these tasks if the seam is not very critical. But if you need to do the job efficiently, then we recommend purchasing a good machine that operates in a wide range of welding current.

To weld an aluminum part, in addition to a semi-automatic machine, you will need tungsten electrodes and shielding gas. Typically the gas used is argon or carbon dioxide, sometimes a mixture of argon and helium.

In some cases, when welding semi-automatically in a carbon dioxide environment (or any other inert substance), only welding equipment can be used. Of course, the quality of the seam will be noticeably worse, but if you need to quickly fix something, then there is no need to transport a heavy gas cylinder.

For semi-automatic welding without gas, you will need a special flux-cored wire. When melted, it releases vapors that have properties similar to a protective gas. In general, semi-automatic welding without gas is a completely economical way to weld in hard-to-reach places.

Now let's move on to individual nuances related to the choice of the semi-automatic machine itself. A semi-automatic welding machine for working with aluminum must meet some important criteria. First, the diameter of the hole in the hose from which the aluminum welding wire will be supplied must be larger than the diameter of the wire.

This is easy to explain: the semi-automatic aluminum welding wire can expand when heated. And if the diameter of the hole is equal to the diameter of the wire, then at a crucial moment it may simply stop feeding correctly into the welding zone.

In the worst case, it will get stuck completely, and you will spend a lot of time trying to remove it.

The length of the hose itself, through which the aluminum welding wire is fed, should not exceed three meters, so as not to deform the wire inside.

Try not to bend or twist the wire hose. After all, aluminum is a metal that can easily be deformed.

Welding wire for a semi-automatic machine, being and moving in the hose, can also be deformed due to excess friction force. To avoid this, make sure that the wire feed channel is coated with Teflon. Also, the welding wire for a semi-automatic machine must be fed by a mechanism equipped with four rollers. Such a mechanism will not jam or deform the wire during operation.

If the quality of the seam is more important to you than the speed of work, then choose TIG welding in argon. If speed is more important than quality, then feel free to purchase an inverter welding machine for working with aluminum. Such equipment is cheaper and sometimes you really shouldn’t overpay for unnecessary functions.

Setting up a semi-automatic machine

It’s not enough to choose a machine for welding aluminum; you also need to configure it correctly. As we wrote earlier, the outcome of your work largely depends on the correct settings. Most likely, you will not be able to find the right settings the first time, since this is a matter of experience. You can watch dozens of training videos and read articles, but that's not enough. You need your experience.

However, we will try to simplify the task of your first acquaintance with a semi-automatic welding machine and give you a few recommendations that always work. First of all, the semi-automatic welding machine for aluminum welding has its own functions. In a standard semi-automatic machine, you can adjust the current strength, voltage value, wire feed speed and polarity.

There are no specific universal settings that you can use to weld any parts. Here you need to build on the thickness. As an example, let's take a part made of aluminum 2 millimeters thick. We recommend welding such metal by setting the voltage to no more than 15 volts; the current can be set in the range from 100 to 150A.

Set the wire feed speed based on the speed of your work. If you are a beginner, then set the minimum speed on your welder. Although welding aluminum must be done quickly. Set the polarity to straight (if you cook using gas). If you work without gas, then set the polarity in reverse.

If you have a professional or semi-professional semi-automatic machine with the ability to operate in four-stroke mode, then turn it on. This will significantly improve the quality of the seam.

Welding technology

Semi-automatic aluminum welding technology is the last thing you need to learn for a quality result. Have you figured out the nuances, chosen welding equipment and set it up? So it's time to get to work.

As we wrote earlier, first you need to prepare the metal. Clean the surface thoroughly using a combination of cleaning methods. There should be no pockets of corrosion, traces of dirt, dust or oil. Degrease the metal surface with a solvent.

Make sure the wire feed hose has a larger diameter than the filler material. Load the wire into the feeder, prepare the gas and turn on the welding machine. If you use the TIG welding method, prepare the electrodes.

Light the arc. Make sure it burns steadily throughout the entire welding process. The distance between the weld pool and the arc should be no more than 15 millimeters. Also try to monitor the wire feed speed. If you feel confident, then increase your speed. But there is no need to set the maximum value, since the metal will not be able to boil properly.

Keep the arc straight, try to form the seam evenly. After the work is completed, smoothly move the arc to the side. There is no need to immediately stop the gas supply; wait 10 seconds and only then close the valve on the cylinder. This will protect the still hot seam from exposure to oxygen.

Instead of a conclusion

Wire welding in shielding gas and using a semi-automatic device is not the simplest, but it is an economical and completely doable method at home. Of course, many nuances need to be taken into account. This is not resistance welding, which does not require anything other than equipment and the parts themselves. Here it is necessary to strictly follow the welding technology and try to avoid mistakes.

If you are a beginner welder, watch additional instructional videos to better understand this aluminum welding method. Well, experienced welders can share their experience in the comments to this article. We wish you good luck in your work!

Source: https://svarkaed.ru/svarka/svarka-metallov/kak-svoimi-rukami-svarit-alyuminij-poluavtomatom.html

Do-it-yourself semi-automatic aluminum welding technology

Aluminum structures are lightweight, corrosion resistant and easy to install using hardware.

Welding of this material is also possible, but the operation is very difficult to perform using conventional welding materials and devices. For high-quality aluminum joining by welding, semi-automatic devices are sometimes used.

How aluminum welding is performed semi-automatically and what materials are used will be described below.

Special properties of aluminum

To perform welding operations correctly, you should know the characteristics of this material. Among the most important physical and chemical properties of aluminum are the following:

• does not change color when heated;
• aluminum and its alloys have too wide a range of melting temperatures;
• The thermal conductivity of the metal is several times higher than that of steel alloys.

An inexperienced welder should remember the above-mentioned features of the metal and take precautions to avoid injury or damage to the surface being welded.

When performing welding work, it is necessary to take into account the formation of an oxide film, which melts at a much higher temperature than the base metal.

In order to melt the oxide layer without damaging the metal surface, it is recommended to properly prepare the material, as well as adhere to the basic rules for welding low-melting metal.

Basic rules for high-quality aluminum welding

Aluminum welding has features that must be taken into account when working.

The main tasks facing the welder:

1. Remove the oxide film from the surface to be welded. For this purpose, you can use a mechanical method. The work can be done with a regular metal brush. You can also get rid of the refractory film chemically or turn on the pulse operating mode on the welding machine. A semi-automatic device with a pulsed operating mode allows for better removal of the oxide layer by instantly heating the surface to the melting temperature.
2. Ensure that the metal is heated in the required temperature range. The difficulty in welding aluminum lies in the fact that with the higher thermal conductivity of the metal, an untrained specialist can make a serious mistake, which consists in excessively heating a small area of ​​the surface being welded. In this case, an instant burn through the aluminum may occur with the impossibility of restoring the previous geometry of the workpiece. To prevent such a situation, the welder needs to be able to correctly select the wire feed mode and its size.
3. Prevent metal warping when cooling. Aluminum has significant linear shrinkage when cooling, so in order to prevent metal deformation at the site of weld formation, it is necessary to complete the welding process with a lower current. On the contrary, it is necessary to start welding with a higher current supply to quickly melt the oxide film.

Welding aluminum using argon

Joining aluminum in an argon environment has undeniable advantages over a method that uses a special flux-cored wire for welding without gas.

connection technology without gas.

Working with aluminum in a protective gas environment allows you to obtain a better quality seam, which will ensure absolute tightness between the parts being welded.

A good result when using argon welding can be achieved only if the semi-automatic machine is correctly configured and high-quality consumables are purchased. The qualifications of the master are also of great importance for performing argon welding.

If the work is being done for the first time, then as a trial option it is recommended to first experiment on unnecessary aluminum parts.

The process of performing a welding operation must be carried out in the following sequence:

1. Remove the oxide film using a wire brush or solvent.
2. Warm up the parts to be welded to +150-300 degrees, depending on the thickness.
3. Bring the torch to the surface to be welded, light the arc and weld the metal.
4. Upon completion of aluminum welding, it is necessary to extinguish the arc and wait until the gas supply is completely stopped.

When welding in a carbon dioxide environment, the sequence of actions will not change, but the complexity of the work will increase significantly due to the excessive formation of an oxide film during metal welding.

Regardless of the type of inert gas used for welding aluminum, the torch must move very smoothly over the surface to be joined.

The process of welding this type of metal is not complicated, but only if the semi-automatic welding machine for welding aluminum has been correctly configured. Much attention should be paid to the choice of filler materials used for the connection.

Setting up the device and materials used

If the semi-automatic machine is configured correctly, you can achieve a smooth seam and the absence of areas with a through burn through the metal.

First of all, you need to set the voltage and current correctly. Approximate values ​​are as follows:

• when the thickness of the metal being welded is 2 mm - voltage 15 V;
• current strength 140-150 A.

The wire must match the type of aluminum alloy. Typically, wire with a diameter of 0.8-1.2 mm is used.

The above welding machine setting values ​​are averaged and can be adjusted either up or down during the welding process.

Aluminum welding with reverse polarity direct current

The use of alternating current for welding aluminum is most often used, but the work can be done no less efficiently using direct current of reverse polarity.

This version of argon welding of aluminum is carried out in the following sequence:

1. A negative contact is connected to the parts being welded, and a positive contact is connected to the electrode.
2. Switch on the supply of protective gas.
3. The metal is welded with a vertical tilt of the torch no more than 20 degrees.

When performing a welding operation with direct current of reverse polarity, it is recommended not to lift the torch from the surface to be welded by more than 15 mm, otherwise the arc may die out. The technology of the operation does not allow oxygen to enter the welding seam, which allows for high-quality connections without the formation of voids and impurities inside the metal.

This method uses argon or any other inert gas as an inert gas.

Pros and cons of argon connection

Welding aluminum semi-automatically in argon with your own hands has both advantages and significant disadvantages.

1. The advantage of the method is the ability to better control the arc discharge process, preventing excessive heating of the metal, while at the same time melting the aluminum surface at the joint as quickly as possible. Thanks to the use of inert gas, it is possible to obtain a better quality seam, free of porosity and foreign inclusions.
2. The disadvantage of this method is the high cost of equipment and consumables.
3. If you need to perform a small amount of work, then it is cheaper, faster and easier to use the services of professional welders.

The method of joining aluminum parts requires proper preparation of materials and adjustment of equipment, which is not easy for a novice craftsman to do on his own. If you decide to master argon welding of aluminum yourself, then the tips and videos presented in the article will allow you to correctly carry out the basic equipment settings and select consumables.

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Source: https://plavitmetall.ru/svarka/alyuminiya-poluavtomatom.html

Features of semi-automatic aluminum welding – technology and equipment

Semi-automatic welding of aluminum is a process that requires not only certain skills, but also knowledge of the characteristics of this material, which is quite difficult to weld. However, almost anyone can master this complex process by spending not much time on it and applying their efforts and desire to learn new useful skills.

Semi-automatic aluminum welding process

What are the features and difficulties of welding aluminum parts?

The main difficulty in joining aluminum parts by welding is that on the surface of this metal there is always a refractory oxide film that must be removed. If you neglect this requirement, it will be very difficult to weld aluminum, and the resulting compound will be of very low quality.

Welding aluminum semi-automatically or using any other equipment is also complicated by the fact that this metal has very high thermal conductivity and a low melting point. It is because of this that aluminum workpieces are often burned and deformed during welding.

Cleaning an aluminum workpiece with an angle grinder

Preparing parts made of aluminum and alloys based on this metal for welding must solve two problems at once: removing the refractory oxide film from the metal surface and eliminating the possibility of deformation of the workpieces being joined during the welding process.

The film is removed by mechanically cleaning the joint area with metal brushes, files and grinders or special fluxes. To avoid deformation of the parts being joined during the welding process, they are preheated in ovens or using a gas burner.

High-quality welded connection of aluminum parts

Equipment requirements for semi-automatic aluminum welding

Semi-automatic welding of aluminum can be performed on any equipment, but pulse welding machines can achieve better results.

Inverter devices (TIG), on which welding is performed using high-frequency alternating current, also provide high quality of the resulting connection, but the process on them is three times slower compared to pulsed equipment.

However, for those home craftsmen who are going to weld aluminum parts with their own hands, TIG machines are the best choice.

The technology for semi-automatic welding of aluminum involves the use of shielding gas, which is argon or a mixture of this gas with helium (if it is necessary to weld workpieces of large cross-section). In some cases, semi-automatic welding of this metal can be carried out without gas, but then it is necessary to use a special flux-cored wire, the evaporation of which forms a protective environment, or to carry out the process under a layer of flux.

A semi-automatic welding machine for aluminum must meet a number of requirements that take into account the characteristics of both the parts being welded and the consumables used to make the connection. Among these requirements, the following should be highlighted:

• The diameter of the hole in the tip through which the welding wire is fed must have some margin in its size. This requirement is explained by the fact that the aluminum wire used for welding expands significantly during the heating process, which can lead to it getting stuck in the feed hole.
• The semi-automatic hose through which the welding wire is fed should not be too long (no more than 3 meters), which is explained by the softness of the aluminum wire used, which can be deformed. It is not allowed for such a hose to have twists or strongly bent areas.
• To minimize the friction force of the welding wire fed through the semi-automatic hose, it is recommended to replace the conventional feed channel with a Teflon one.
• To ensure that the feed mechanism of the semi-automatic welding machine does not jam the soft aluminum wire, it must be equipped with 4 rollers with U-shaped grooves. The use of such a feeding mechanism will ensure minimal mechanical impact on the surface of the wire.

Four-roller mechanism ensuring smooth feeding of aluminum wire

If you are going to weld aluminum workpieces with your own hands quite often and the performance of this technological process is important to you, then it is better to use specialized equipment operating in pulse mode for these purposes. This semi-automatic machine initially has a synergetic welding mode, which makes it possible to effectively use this device for joining parts made of aluminum.

If you are primarily interested in the quality of the weld being formed, and not the speed of the technological process, then it is better to use the above-mentioned TIG inverter for welding aluminum parts in an argon environment. Such equipment is much more expensive, but ensures high quality of the weld, its uniformity and the absence of pores.

Inverter semi-automatic machine of the Kedr brand with an external wire feed mechanism

Aluminum welding conditions

Aluminum, being a metal with high strength characteristics, requires special conditions when performing welding. If these conditions are met, you can weld parts from this metal with your own hands.

• The surfaces of the workpieces to be joined must undergo mandatory cleaning from the oxide film, for which mechanical or chemical methods can be used.
• It is necessary to use a tip with a hole larger in diameter than the diameter of the welding wire.
• Welding should be performed in a shielding gas, which is predominantly argon.
• It is necessary to monitor the stability of the welding arc length. The interval of this parameter should be 12–15 mm. You should also control the speed of welding, which should not be too high (otherwise it will not be possible to achieve high-quality welding of the parts being connected).
• If welding is performed without the use of shielding gas, it must be performed using flux cored wire or under a layer of special flux. Protection of the welding zone is necessary in order to minimize the influence of negative environmental factors on it, as well as to prevent the formation of a refractory oxide film on the surface of the parts being joined.
• To ensure that the formation of the weld is not accompanied by its deformation, the supply of shielding gas should be turned off not immediately after the end of the welding process, but after 5–7 seconds.
• The use of a four-stroke pulse mode allows you to achieve good results when performing semi-automatic welding of aluminum.

Compliance with the above conditions for performing semi-automatic welding of parts made of aluminum and alloys based on this metal does not guarantee high quality of the formed joint if the operating modes of such a technological process are incorrectly selected.

How to configure the equipment correctly

The complexity of welding aluminum is due not only to the chemical properties of this metal, but also to the need to strictly adhere to the optimal modes for performing this technological operation. In order to thoroughly understand the rules for performing such a complex process, it is not enough to simply watch a training video; it is important to understand the nuances of this operation.

The features of the process under consideration, which the training video will not tell you about, include the following.

• Before starting welding, it is important to correctly select and set the operating modes of the semi-automatic machine (voltage, current, welding wire feed speed, polarity).
• In order for the resulting weld to have the required quality and reliability, it is necessary to select the right consumables.
• If you watch a video demonstrating semi-automatic welding of aluminum, you will notice that this process is accompanied by the formation of a large amount of soot. This should also be taken into account when performing such a technological operation.

Like any complex technological process, welding aluminum parts using a semi-automatic machine requires careful preparation, which includes the following activities:

• tips for welding equipment are selected that are optimally suited for filler wire of a certain diameter;
• the surfaces of the parts that need to be cooked are thoroughly cleaned;
• semi-automatic welding modes are selected, which depend on several parameters: the thickness of the parts to be joined, the type of connection, etc. (to make it easier for you to select welding modes, you can use special tables or parameters that are specified by the requirements of the relevant GOSTs);
• When welding aluminum semi-automatically, the tip of the device is positioned at the required angle to the surface of the parts being joined.

Scheme of welding when welding aluminum

When welding aluminum, which has high thermal conductivity, it is very important to control the degree of heating of the workpieces being joined in order to prevent them from overheating and, as a result, deformation.

Selecting machines for semi-automatic aluminum welding

For aluminum welding, which you are going to do yourself, it is very important to choose the right equipment that allows you to obtain a high-quality and reliable connection.

When choosing a suitable unit, a number of parameters should be taken into account.

Equipment power

If you are going to weld aluminum all the time, it is better to choose a professional-type semi-automatic machine with high power.

Welding machine operating mode

Optimal in terms of its characteristics is equipment operating in pulse mode (PULSE). The use of such a semi-automatic machine not only ensures the destruction of the oxide film and prevents the risk of burning through the parts being joined, but also guarantees a high-quality and reliable weld.

Voltage type

Some models of welding equipment can operate from a conventional electrical network, but more stable operation is demonstrated by those that are connected to a three-phase electrical network with a voltage of 380 V. Such devices ensure the stability of the welding arc and uniform distribution of the load on the electrical network.

The choice of equipment for welding work with aluminum and alloys based on this metal is also influenced by the brand under which it is produced. Among experienced specialists, semi-automatic devices from German and Italian manufacturers, as well as domestically produced devices, are very popular.

Welding parts made of aluminum and alloys based on this metal is a rather complex technological process, the implementation of which should be carried out only by qualified specialists with experience in this field.

Source: http://met-all.org/obrabotka/svarka/svarka-alyuminiya-poluavtomatom.html

How to weld aluminum semi-automatically for beginners

12.04.2019

During critical repairs of aluminum parts and installation of profile frames, electrodes cannot be used to make reliable connections. When welding aluminum semi-automatically, the seams are of high quality. It is possible to weld light metal by electric arc welding in argon or carbon dioxide using special refractory electrodes and filler wire, but semi-automatic welding is the most effective and reliable method of processing aluminum alloys.

If aluminum is welded semi-automatically without gas, protective fluxes are used or a special multi-component flux-cored wire is used, which, when heated, creates a gas cloud that prevents oxidation.

Features of semi-automatic aluminum welding

Light metal is difficult to weld due to the oxide that forms on the surface when exposed to air. The oxide film must first be removed from the parts; depending on the alloy, it burns out at +2050 – +2200°C, and the melting point of aluminum is only +660°C.

Aluminum alloys have high thermal conductivity: parts quickly warm up when heated and immediately cool down as soon as the heat source disappears. During heat treatment, internal stresses arise in aluminum workpieces, causing cracks to appear in the seam.

When deciding how to weld aluminum semi-automatically, it is necessary to provide for preliminary heating of the workpieces with a gas burner to +150 - +190°C. Experts use linings that remove heat; they prevent the aluminum from getting too hot and cooling quickly. It is important to adhere to the welding mode so as not to burn through thin parts.

Which semi-automatic machine is suitable for aluminum welding

Manufacturers offer a wide range of household and welding equipment. There are compact models that generate current of various parameters.

Functional

When choosing a semi-automatic welding machine for welding aluminum for a private workshop or car service, it is better to choose devices with the TIG function that generate high-frequency pulsed current. They are equipped with a “PULSE” mode. Working with them reduces the risk of burns and maintains a stable short arc. With TIG inverters without a pulse unit, the work is three times slower, but the connection quality will also be high.

Simple inverters with MIG/MAG functions are used for domestic purposes; argon and carbon dioxide can be connected to them. It is difficult to make a high-quality connection with such inverters; they are designed for low currents. There is no need to pay for additional features. The more complex the equipment, the greater the risk of failure.

Source: https://svarkaprosto.ru/tehnologii/kak-varit-alyuminij-poluavtomatom

Semi-automatic aluminum welding technology: equipment requirements

Semi-automatic welding of aluminum is a reliable and economical way to create permanent connections of parts made of aluminum alloys . A number of physical and chemical features of the metal complicate working with it, therefore, when preparing and welding, it is necessary to strictly follow the requirements of the technical process.

Special properties

The main feature of the metal is the appearance on its surface of a layer of oxide, which has a high melting point, three times higher than that of the metal itself . If this layer is not removed by mechanical or chemical cleaning, it will be impossible to weld the workpieces.

The oxide layer forms in the form of a film on the surface of the melt, so the weld pool must be protected from contact with air.

Another feature of aluminum is its high thermal conductivity . For full penetration it is necessary to use high welding currents, this increases the risk of burn-through. Before welding thick-walled workpieces, they should be heated.

equipment requirements

Is it possible to weld aluminum with a semi-automatic machine? Technically, it is possible to weld aluminum using any class of welding equipment. In practice, in production conditions, pulsed current sources are more often used.

In a home workshop, it is more convenient to use an inverter semi-automatic machine operating in an atmosphere of protective gases (TIG) . You can operate such a device without gas, but you will have to use flux-containing welding wire or the part must be welded under a layer of flux powder. The following requirements apply to the equipment:

• the tip feeding the aluminum wire into the working area must have a reserve diameter so that it does not get stuck, expanding when heated;
• the length of the hose supplying wire, voltage and gas is limited to three meters, it is recommended to use Teflon;
• instead of V-shaped rollers, the feeding mechanism must be equipped with U-shaped rollers that do not pinch soft wire;

Tasks of a welder at work

The welder will have to solve a number of problems simultaneously:

• pierce the oxide layer with a pulsed discharge;
• maintain the length of the electric arc within 12-15mm;
• take into account the high degree of expansion of aluminum when heated.

To prevent the workpiece from becoming deformed and causing defects when cooling and shrinking, the weld must be started with a strong current that destroys the oxide layer, and finished with a gradually decreasing current, avoiding large temperature changes.

Technological features

How to weld aluminum correctly with a semi-automatic machine? Argon, helium and their mixtures are used as a protective medium. Carbon dioxide is not suitable . Mixtures with added carbon dioxide are also not used. If the connection is not particularly critical, it is permissible to cook without a gas environment, with flux-containing or self-shielding wire.

When choosing the TIG method, the arc is supported by an infusible tungsten electrode, the wire is used as a filler material. The arc is ignited by a high-frequency pulse.

In the MIG method, consumable electrodes serve as filler material. Welding is done with reverse polarity.

Hardware settings

To correctly configure and select modes, the following must be taken into account:

• modes are selected based on the thickness of the workpiece and alloy composition; the method of cutting edges, selected welding materials, reference tables are given in GOST;
• you should check the functionality of the exhaust ventilation to remove the resulting soot;
• the tips are selected with a margin for thermal expansion of the wire;
• thorough cleaning is carried out immediately before welding;

Direct current reverse polarity

During MIG operation, an electric arc melts the filler material. Ionized melt drops are attracted by the melt surface having the opposite potential. In doing so, they lose their charge and release energy. This destroys the oxide layer that forms on the surface of the melt. After cooling, the melt crystallizes, forming a suture material.

Semi-automatic devices

When choosing a semi-automatic welding machine for welding aluminum parts, you need to pay attention to the following characteristics:

1. Power . Welding aluminum requires a power of 6 kW.
2. Modes . Must support Pulse, TIG and MIG operating modes.
3. Voltage . Household appliances operate on a 220 volt network. If the thickness exceeds 3 mm, it is better to choose a three-phase power supply of 380 volts.

For workpieces of large thickness, it is better to choose a device equipped with a torch cooling system.

How to use?

The following parameters and characteristics should be provided:

Wire

When choosing aluminum wire for semi-automatic welding, you need to consider the following points:

• the chemical composition should be close to the composition of the workpiece material, this will ensure similar melting temperatures;
• diameter from 0.8 to 1.6 mm.

Thus, for alloys with a silicon content of less than 5%, grades ER4043 and ER5356 are used

Operating modes for alloys with low silicon content.

Burner

The hose must have a Teflon wire feed path and a length of no more than 3 meters.

https://www.youtube.com/watch?v=6xalL6Mu9-8

The tip is selected with a margin of up to +0.4 mm relative to the wire diameter.

When operating at currents higher than 200A, a water cooling system for the torch will be required.

Wire feeder

To prevent soft aluminum wire from becoming kinked or stuck, a four-roll feed system should be used . The profile of the rollers should be U-shaped. The mechanism requires fine adjustment of the tension and pressure force after each change in wire diameter.

Gas burner position

When welding with argon using a semiautomatic welding machine, the torch should be tilted 10-20o. The gap between the nozzle and the workpiece must be maintained around 10-15 mm; if you move the burner further, the argon consumption will increase. Move the burner from right to left, or by moving your hand away from you, away from the bath. This allows you to clean the surface of the seam and reduce contamination with slag.

Driving speed

Aluminum should be welded with a fast torch movement, high-temperature electric arc . This allows you to avoid burn-through at high operating currents required to warm up the part.

Convex seams

The connection of aluminum workpieces is at risk of cracking due to the high coefficient of expansion of the material. If a crater has formed on the seam, it serves as a precise stress concentration and the beginning of cracks. The craters formed during welding must be welded until a bulge is formed that strengthens the seam. To do this, move the torch in the opposite direction without extinguishing the arc.

Precautionary measures

When performing work, the following safety precautions should be observed:

• use personal protective equipment against metal splashes and ultraviolet radiation from the welding arc: thick fireproof clothing and shoes, a welder’s mask with an adaptive light filter, and split leather leggings;
• protect the respiratory system with a respirator or individual breathing apparatus with a supply of clean air from a cylinder or from a main line;
• Before starting work, check the serviceability of the equipment, the absence of mechanical damage, insulation damage and gas leaks.

Possible difficulties

Difficulties that can be encountered when welding aluminum include:

• insufficient heating of thick-walled workpieces, leading to incomplete penetration of the edges;
• formation of an oxide layer due to poor quality or premature cleaning;
• the occurrence of cracks due to overheating of the workpiece and subsequent shrinkage;
• the difficulty of determining the temperature of the workpiece “by eye”, since aluminum does not change color when heated;

Advantages and disadvantages

Semi-automatic welding technology is characterized by the following advantages:

• strength and durability of the connection;
• economical consumption of welding materials and energy resources;
• compactness of the equipment.

The method also has a number of disadvantages:

• high cost of equipment;
• the feed mechanism is afraid of dusty rooms;
• difficulties of working at low temperatures.

Conclusion

Semi-automatic welding of aluminum allows you to obtain a strong and durable seam and save resources. It does not require highly qualified welders, but the technology requirements must be strictly observed. The technology is also available for home workshops.

Source: https://svarka.guru/tehnika/opredelennih-metallov/alyuminiy-poluavtomatom.html

Semi-automatic aluminum welding (MIG/MAG) | Tiberis

Aluminum, without exaggeration, is one of the metals most commonly used by humans. But, due to its special chemical properties, welding work on it is much more difficult than with ordinary steel, especially if you are not a welding specialist.

And yet, for this there is a very convenient way that requires less skills - semi-automatic aluminum welding (MIG/MAG), which makes it possible to easily overcome the resistance of the thinnest oxide film of the metal and, as a result, obtain an excellent connection.

You will learn more about this method in our article.

What is semi-automatic aluminum welding?

Semi-automatic welding of aluminum and its alloys (MIG/MAG welding) is carried out using welding wire (some welders use the name consumable electrode) for aluminum and alloys in a gas environment or self-shielding wire. In this case, an inert gas , most often argon, is used to protect aluminum from oxidation. The filler wire is supplied automatically, and the welder moves the torch manually.

Welding aluminum semi-automatically without gas is not recommended for use and is much less common, since in this case:

• the porosity of the seam significantly increases and its strength decreases;
• solidified slag is difficult to separate;
• there is strong metal spattering.

The only serious reason why this welding method is still used is its obvious low cost. Therefore, welding aluminum semi-automatically without argon is common among single artisans who save on the quality of the weld.

Unlike steel, aluminum has much greater thermal conductivity, so when working with it, the wire feed speed increases, and the surface of massive welded products must be additionally heated.

Most often, semi-automatic aluminum welding is used for welding work on an industrial scale, including in the aviation and shipbuilding industries. Moreover, in this case we use:

• high quality inert gas and filler wire;
• the work of professional welders;
• expensive professional equipment.

Together, these three critical factors ensure first-class results.

What is the difference between semi-automatic aluminum welding and the argon arc (TIG) method?

There are only a few main differences:

1. The main difference between the two methods is the type of electrode used. TIG welding uses refractory tungsten electrodes, while MIG welding uses aluminum wire.
2. In addition, the argon arc method is intended only for manual welding.
3. More critical areas are welded using argon arc welding due to the higher strength of the connection.
4. Tungsten electrode welding (TIG) requires more money for consumables (components).

The argon-arc method is very common in production and at home, and therefore deserves a more detailed description, which you can study at the link.

The semi-automatic welding machine for aluminum welding can be equipped with standard functions and with a pulse mode.

The use of the latter gives a greater effect, since under the influence of a powerful impulse the oxide film on the surface of the welded product is instantly broken through.

Each drop of molten aluminum from the wire is pressed into the surface at the moment of the high voltage pulse. The result is a significantly improved weld quality with a significant reduction in metal spatter.

Features and advantages of semi-automatic aluminum welding

Welding aluminum semi-automatically has undoubted advantages, as well as some features. These include:

1. High performance. Compared to argon arc welding, the speed increases three times.
2. Simplicity. This method is much simpler than the argon arc method; even an amateur can easily master it. Therefore, welding aluminum semi-automatically with your own hands seems to be quite commonplace.
3. The importance of having a pulse mode in a semi-automatic machine. Since in this case the efficiency of welding work and the quality of the output seam increase significantly.
4. The need to use high-quality welding wire (additive). Otherwise, the stability and efficiency of the welding process may be seriously affected.
5. For aluminum, the wire feed is most often set to be 15-20% higher than for the same thickness of ferrous metal (steel) and approximately 30 percent more voltage.

Requirements for equipment and consumables

To finally understand the question of whether it is possible to weld aluminum semi-automatically , it is necessary to clearly understand the additional requirements for the equipment and consumables used:

1. The current must necessarily have reverse polarity , because in this case the oxide film is not destroyed.
2. The wire feeder must have four rollers , since soft aluminum easily wrinkles when resistance occurs at the time of feeding. It is important that the roller is U-shaped , smooth and without notches. In the picture on the right, although it is of the correct shape, it has notches - this will not work.
3. The diameter of the wire should be smaller than that of the tip, since aluminum expands more than steel when heated. For welding, we recommend using AlMg5 wire from the link or its analogues.
4. It is advisable to use pure argon as an inert gas, since in this case the maximum quality of the weld is ensured
5. The welding torch must have a special Teflon sleeve in order to reduce friction of the aluminum wire.
6. MIG-MAG welding of aluminum alloys is recommended for thicknesses greater than 3mm and it is important to use a forming backing with a groove.

How to choose the right semi-automatic machine for aluminum welding

Above you have already learned how to weld aluminum semi-automatically. Now it’s time to decide how to navigate among the variety of models and purchase the most suitable semi-automatic option.

The choice is really very extensive. All options can be divided into the following main groups:

Budget semi-automatic machines

These models are perfect for home use. They are compact in size, light in weight and can operate on a regular 220-volt network.

If you intend to do welding work periodically, for your own needs, their capabilities will be quite sufficient.

Examples of models in this group are Svarog EASY MIG 160 or Svarog PRO MIG 160. The second model can operate in two- and four-stroke mode and provides arc afterburner.

Middle class semi-automatic machines

They have more outstanding technical characteristics (high current, smooth control of current and wire feed speed). But they, like budget models, need some adjustments - adjusting the burner and replacing rollers.

Among other models, we can note the Finnish KEMMPI MinarcMIG EVO 200 and the American Lincoln Electric Speedtec 200C

Middle class semi-automatic devices with pulse mode

They are multifunctional devices with many built-in welding programs. The presence of a pulse mode ensures the highest quality of the weld, and reliable components guarantee long-term use.

Excellent examples of models in this group are Helvi TP 220 and EWM Picomig 180 Puls.

Industrial models with pulse mode

They operate on a voltage of 380 V and are equipped with a liquid cooling system. Provide maximum labor productivity during welding with high quality seams. Easy to operate and developed using the latest technology.

Worthy representatives of this group are EWM Phoenix 501 Puls and EWM Phoenix 401.

The use of semi-automatic welding machines for aluminum welding is a very thoughtful and correct decision that many practical people have made. At Tiberis you always purchase these devices on favorable terms.

welding aluminum with semi-automatic welding machine

material for visual reference, which shows the process of welding aluminum with a MIG/MAG machine. This is not an instructional video.

Source: https://www.tiberis.ru/stati/svarka-alyuminiya-poluavtomatom

Welding aluminum semi-automatically with gas (argon) and without

Devices in which a wire acting as an electrode and shielding gas are supplied to a welding gun when a button or trigger is pressed have appeared for quite some time. Their initially high price gradually decreased.

They appeared not only in the arsenal of large enterprises, but also became available to people wishing to purchase such equipment for their own needs.

And yet, despite the significant number of articles and videos posted online, the conditions under which this process takes place remain not very clear to many.

Let's dispel the myths

We will try to clarify a topic that interests many. And to avoid misunderstandings, let’s try, first, to get rid of the speculations and myths that haunt popular technology.

• Pure aluminum is almost never used in production because it does not have all the necessary mechanical properties. In most cases, manufacturers have to deal with aluminum alloys or, at a minimum, metal saturated with various additives.
• Pure aluminum is toxic, but is not capable of causing harm to humans upon contact, since it is almost instantly covered with an oxide film. Thus, we come into contact with aluminum oxide and the statement that before welding the metal oxides should be removed from its surface loses all meaning. In fact, the surface of the parts to be welded must be cleaned of contamination.
• In atmospheric conditions, welding aluminum semi-automatically without gas is impossible. The place where the suture is applied must be protected from the influence of the external environment. Even if the gas is not supplied with the welding wire, it is generated when the flux used is burned, thus providing the necessary protection. There are electrodes with a coating that releases protective gas during combustion, but they are not used in semi-automatic devices.
• Mig welding is not the name of the technology, but a term that appeared in our country thanks to the appearance of MIG brand semi-automatic machines on the market. In fact, aluminum welding can be carried out using equipment from any company; fortunately, there is now no shortage of different manufacturers. The main thing is that the device used is of high quality and in good working order. Is it possible to make a semi-automatic welding machine yourself? In principle, yes, but will it be cheaper than the factory one and meet all the necessary requirements?

Facts are stubborn things

Having finished with the myths, let's move on to the real facts that really influence the work with promising, but not very obedient material.

• The simplest way to ensure protection of the welded area of ​​the parts from the influence of the external environment is to supply argon under pressure. This noble gas is quite accessible, although it is somewhat more expensive than carbon dioxide used when working with steel. Good results are obtained by using a mixture of argon and helium. Since we have already found out that welding aluminum semi-automatically without argon is impossible, then in the absence of gas we will have to get flux somewhere.
• The composition of fluxes for aluminum welding, as a rule, includes salts of alkali and alkaline earth elements and, in small quantities, fluoride components that activate the chemical process. There are many recipes of different compositions, selected depending on the characteristics of the metal with which you have to deal. Thus, AN-A1 and AN-A4 fluxes are well suited for welding widely used aluminum-manganese alloys. When using them, the connecting seam is smooth, uniform and does not contain foreign inclusions.
• Even when using shielding gas, the best results can be obtained by treating the surface of the parts to be joined with flux. However, such processing takes some time and slows down the progress of work.
• In industrial conditions, it is best to use equipment that uses the principles of pulsed welding for work. It is with its help that the optimal result is achieved. Due to the relative complexity and high cost of such equipment, inverter semiautomatic welding machines are becoming increasingly widespread. Without being too inferior in quality as a connecting seam, they are simpler and can easily be used even at home.
• Particular attention should be paid to the quality of the welding wire. Its chemical composition varies and must be selected taking into account the chemical composition used for the manufacture of aluminum alloy parts. Low-quality wire, which does not have a uniform cross-section and has low mechanical properties, makes work difficult and often leads to equipment damage.

Special requirements

The mechanical characteristics of the wire used for aluminum welding force certain requirements to be placed on the design of semi-automatic machines and their operation.

• It is unacceptable that the length of the supply hose exceeds three meters, and its protective braiding is prone to twisting or kinking. It is important that the channel through which the wire passes is as smooth as possible, without sharp turns. It is optimal if the supply channel itself is made of Teflon.
• The feed mechanism must pull the wire without jerking, providing minimal mechanical impact on its surface. Its components should be inspected promptly for damage and lubricated frequently to ensure free rotation of the rollers.
• The best results can be obtained with equipment whose design provides for the possibility of smooth and precise adjustment of all parameters. Everything is important - the current strength, the speed at which the wire is fed, the amount of incoming gas. Since the influence of the external environment can affect the quality of the weld during its formation, stopping the gas supply should not occur simultaneously with turning off the current, but with a delay of about 5 - 7 seconds.

Semi-automatic welding of aluminum requires certain skills and craftsmanship from the specialist involved in it. And although watching a video of how professionals work is not a problem, you should not follow their recommendations recklessly.

This information is best used as a starting point from which you can experiment and gain experience yourself.

This is important because materials that differ in composition and thickness behave differently, as do semi-automatic devices produced by different manufacturers.

Advantages and disadvantages

To summarize, it is worth noting that semi-automatic welding of aluminum is convenient, but still not ideal. It has its advantages and disadvantages.

When assessing the benefits, the following are undoubtedly worth mentioning:

• Relatively low cost of the process compared to other technologies. Thanks to this, it is accessible to both large enterprises and private professionals.
• Versatility of equipment. It can be used to weld various materials. It is enough to simply replace the gas and wire supplied to the welding gun and make not too complicated adjustments.
• Availability of necessary materials. As the technology grew in popularity, there was no shortage of wire, gas and fluxes.
• High speed of work execution, preparation for which also does not take much time.

As for the disadvantages, they include:

• Mandatory use of shielding gas or fluxes. Without them, the connection quality will be extremely low
• The difficulty of selecting welding wire in the absence of information about the composition of the material from which the parts are made.
• The speed of the process requires skill from the welder. People with poor reactions may not be able to master aluminum welding with a semi-automatic machine.

You can delve into the features of technology for a very long time, because a lot of serious scientific ponds have been written on this topic. But we hope that the information presented will be enough to evaluate the capabilities of the process at the first stage and decide on the need to use it.

Source: https://svarkalegko.com/tehonology/svarivaem-alyuminij-poluavtomatom.html

How to weld aluminum correctly with a semi-automatic machine?

Welding aluminum is a rather difficult task that only skilled welders can handle. Aluminum is a capricious metal; to weld it semi-automatically, you must use a high-quality inverter.

As a rule, any semi-automatic machine is suitable for this work, but the quality of the weld can only be ensured by a welding inverter with a special aluminum welding function. In addition, if the aesthetic appearance of the workpiece is important to you, then be sure to use a machine with a pulse welding function.

A welding inverter with AC argon arc welding is also suitable. Semi-automatic aluminum welding is popular due to its high speed.

Diagram of a semi-automatic machine for aluminum welding.

What requirements must be met?

When working with aluminum, pure argon or its mixture with helium are used, which act as a shielding gas. The second option is most often used when working with thick sheets. Before starting work, stock up on aluminum welding wire for semi-automatic machines; its cross-section should be solid.

Table of characteristics of electrodes for welding.

The burner must be located on a straight hose no longer than 3 m without kinks or twists. This is due to the fact that aluminum wire is very soft. It is recommended to replace the usual channel in the burner with Teflon, which is specially designed for processing aluminum.

If the length of the torch hose is not enough for your work, then you can bring the device closer to the workpiece. If this is also not possible, then only a semi-automatic machine with a separate feeding mechanism will be suitable for your work. Also note that it is necessary to use tips with a larger hole than for welding steel, since aluminum expands more.

Not all electrodes are suitable for aluminum welding. For better results, you can use one of the following types of electrodes:

• OZANA-1 AND OZANA-2;
• OK 96.10, OK 96.20 AND OK 96.50;
• non-consumable electrodes.

Electrodes belonging to the first category became widely used a little more than 10 years ago. They process technical aluminum of grades A3, A2, A1 and A0. In addition, they are suitable for working with casting defects and aluminum alloys. These electrodes are capable of providing an even arc, a weld similar in properties to the base metal, and the ability to easily separate the slag crust.

Electrodes of the second category have an alkali-salt coating. They are applicable to work with various alloys of this metal, depending on the type of electrode. In most cases, they require preheating to +150-300°C.

Aluminum can also be welded using non-consumable tungsten electrodes. They ignite the welding arc and maintain its stable operation. Their diameter varies from 2 to 6 mm, the optimal diameter for each individual case is determined taking into account the thickness of the workpiece. Pure tungsten electrodes perform worse than electrodes with various additives, such as chicory.

Welding aluminum with an inverter involves the use of expensive electrodes, so you need to carefully select the option that is suitable for your work.

Welding Features

Diagram of the semi-automatic aluminum welding process.

Difficulties in welding aluminum primarily arise from the oxide film that appears on its surface during processing with a welding machine. The temperature at which this oxide film melts is about +2050°C, which is much higher than the melting temperature of the base material.

Welding technology implies that the oxide film will be broken through, and then the metal itself will melt. The pulse welding method is ideal for this. Since aluminum conducts heat well and melts at a relatively low temperature, there is a risk that the part will catch fire during welding. This can be avoided if you warm it up a little before cooking the aluminum. Preheating the part will increase the depth of its penetration.

Before welding, it is necessary to clean the workpiece with a wire brush to make it easier to break the oxide layer.

It will be easier to break up the oxide layer if you clean the workpiece with a wire brush before welding. The part will be better melted, and the process will take less time. It is necessary to start cooking the part within 24 hours after cleaning.

During operation, care must be taken to maintain a constant arc length. This rule is universal; it also applies when welding other metals. If the arc length is longer than required, the part will not melt, but if it is shorter, it will ignite. The required arc length depends on the chemical composition of the material being processed, since the thermal conductivity of different alloys is different. The average value for aluminum is 12-15 mm.

It can be quite difficult to weld a crater at the end of a seam. This is due to the fact that aluminum cools quite quickly. This problem can be eliminated if you use a special semi-automatic machine, which at the very beginning of the welding process gives a strong current that penetrates the oxide film well, and then a lower current, which allows you to easily weld a crater at the end of the seam.

Thus, to weld aluminum of the required quality, it is necessary to use special equipment suitable for this purpose. Electrodes for aluminum welding must have certain parameters. In addition, this metal has some specific features that must be taken into account when working, otherwise you risk damage to the processed parts and consumables.

Source: https://moyakovka.ru/instrumenty/kak-varit-alyuminii-poluavtomatom.html

How to cook aluminum semi-automatically?

Welding aluminum using a semi-automatic machine involves the use of a special electrode in the form of a soft wire, which must be fed to the welding site through a special sleeve; this occurs due to a special roller system. If you have some experience in the field of welding, as well as if you have a semi-automatic machine, you can slightly change the approach to this technology.

Before you start welding aluminum with a semi-automatic machine, you should take into account that this metal is much softer compared to steel, so you need to feed the electrode wire much faster than when working with other metals.

Another property of aluminum products is very high thermal conductivity, which forces the use of high currents. Only in this case will it be possible to obtain a good and sealed seam and weld the metal properly. If the work continues long enough, the impulses may decrease somewhat. When welding aluminum, the use of significant current makes it possible to reduce the applied effort and reduce the time of use of the equipment, respectively, extending its service life.

Which device is better to use?

To weld aluminum products of significant thickness, you will need to take a fairly powerful machine. If the work will be carried out regularly, then it is necessary to purchase equipment whose power must be at least 200 A. It is much more comfortable to weld aluminum with a special semi-automatic machine if the machine is equipped with a pulsation mode. It will easily break through the oxide film that forms on the metal surface upon direct contact with air.

The pulse output mode prevents overheating of both the workpieces themselves and the apparatus; accordingly, burning through the metal will be quite problematic. This also affects the creation of a high-quality welded joint.

For a reliable weld, it is advisable to use argon welding technology, and you can use either pure gas or with a small addition of helium. This fact greatly distinguishes the work from welding steel, which requires creating a carbon dioxide environment.

If the device has a gearbox and regulator designed specifically for carbon dioxide, they will need to be replaced.

It is best to use a wire made of aluminum as an electrode. If its diameter is 0.8 mm, the nozzle must be at least 1 mm - this is due to the fact that aluminum seriously expands when heated.

A semi-automatic welding machine for aluminum must have a feed mechanism with grooves made in the shape of the letter U. Standard grooves are shaped like the letter V - they are not suitable for this material. It would be optimal to use a device whose mechanism has four rollers at once. If this is not provided for, then the workpieces can be seriously damaged during welding work with your own hands.

The cable channel through which the aluminum welding wire will be fed should be made of graphite or Teflon - this allows friction to be kept to a minimum. The welding torch cable should be no more than three meters.

Features of the work

Welding aluminum semi-automatically without argon involves constantly maintaining a burning arc, and its length is much longer than when working with steel - about one and a half centimeters. If you make it shorter, there is a danger of burning through the workpiece and not fusing the edges. The main technological features of welding aluminum with your own hands are as follows.

• An aluminum electrode is inserted into the wire feeder and immediately pulled to the torch.
• On the front panel of the device you need to configure all the necessary indicators related to current, voltage, power, and so on.
• The system includes an argon cylinder.
• The workpieces must be cleaned by removing the oxide film and removing all contaminants.
• They begin to melt the crater in the area where the workpieces join, and gradually fill it with liquid metal.
• The resulting depression is filled with aluminum until the seam is completely formed.

The polarity is adjusted so that it is reversed, that is, the negative charge will be supplied to the workpiece itself, the positive part will be supplied to the electrode. It is advisable to connect a semi-automatic welding machine for welding thick aluminum to a cylinder, which should contain a mixture of argon and helium. If the workpiece is quite thin, then gas can be used in its pure form.

It is understood that the workpieces must be prepared for welding. If you ask an experienced welder about this stage, he will say that the surface of the parts in the area where the seam is formed must be cleaned and degreased. When sufficiently strong contamination is formed during direct welding, no more than 3% oxygen can be added to argon. This will burn out all the dirt that appears in the area of ​​​​the forming seam.

https://www.youtube.com/watch?v=KvLFpEPSKe4

It is advisable to weld the crater at the future joint. It can be broken through using pulsed technology of applying voltage to the electrode. When the work comes to an end, the seam should be completely covered with molten metal. In the future, it will need to be allowed to cool to 400 degrees in an argon environment. If you lose sight of this point, this will lead to the formation of an oxide film on the surface of the welded joint. This will cause a decrease in the strength of the seam.

Semi-automatic aluminum welding: positive aspects

Regarding how to weld aluminum, there are several recommendations to make the work easier.

• Semi-automatic technology for welding aluminum is not too expensive, its price in terms of cost is lower compared to argon and other technologies.
• Semi-automatic welding can be used for various materials. It is a universal technique that most professional welders work with.
• The welding itself is carried out quite quickly, largely due to the fact that the filler material or electrode wire is supplied independently using a special mechanism.
• The welding wire required for working with aluminum is not in short supply - it can be purchased at a low price.
• Equipment and workpieces are prepared quite quickly, and everything is cleaned up in a short time.

However, it is worth considering that when welding, the seam will not be very strong if you do not use gas such as argon. Without using argon, you must use flux. Often it is not aluminum that needs to be welded, but its alloys. If you do not know exactly what metals the workpiece consists of, as well as their ratio in the alloy, then choosing the most suitable wire is very problematic. The electrode needs to be moved quite quickly, which makes it quite difficult to form a normal roller.

However, the main difficulty that arises when it is necessary to weld aluminum is the presence of a special oxide film on the surface of the workpiece, which can only be melted at a temperature of more than 2 thousand degrees, while the aluminum itself melts at a lower temperature.

Due to too much expansion when heated, the parts will greatly shrink in size when cooling, which ultimately will lead to the fact that the seam can easily burst or the workpieces will undergo a certain deformation.

All these factors must be taken into account before starting work.

Safety Basics

Be sure to use various respiratory, skin and vision protection. In particular, before starting work you need to wear a respirator, a protective mask, and special thick clothing that will protect the skin surface from splashes of molten metal. During the work, very acrid white smoke is released, which, if inhaled, causes severe coughing and headaches.

This technology is an ideal solution if there is a need to weld metal or fill a significant gap. In industrial production, this welding technique using aluminum is most often encountered, largely due to the fact that it ultimately allows one to obtain a very large amount of work done, since it is performed very quickly. If the welder is qualified, he will produce excellent products.

Source: https://electrod.biz/oborudovanie/poluavtomat/svarka-alyuminiya-poluavtomatom.html