A Guide to Aluminum Welding

Reprinted courtesy of Welding Design and Fabrication magazine. Equipment Selection, Material Prep, Welding Technique... A Guide to Aluminum Welding Reprinted courtesy of Welding Design and Fabrication magazine.

Follow the rules of thumb offered here for selecting welding equipment, preparing base materials, applying proper technique, and visually inspecting weldments to ensure high-quality gas-metal-and gas tungsten-arc welds on aluminum alloys. Even for those experienced in welding steels, welding aluminum alloys can present quite a challenge. Higher thermal conductivity and low melting point of aluminum alloys can easily lead to burnthrough unless welders follow prescribed procedures. Also, feeding aluminum welding wire during gas-metal-arc-welding (GMAW) presents a challenge because the wire is softer than steel, has a lower column strength, and tends to tangle at the drive roll. To overcome these challenges, operators need to follow the rules of thumb and equipment-selection guidelines offered here... Gas-metal-arc-welding: Base-metal preparation: To weld aluminum, operators must take care to clean the base material and remove any aluminum oxide and hydrocarbon contamination from oils or cutting solvents. Aluminum oxide on the surface of the material melts at 3,700 F while the basematerial aluminum underneath will melt at 1,200 F. Therefore, leaving any oxide on the surface of the base material will inhibit penetration of the filler metal into the workpiece. To remove aluminum oxides, use a stainless-steel bristle wire brush or solvents and etching solutions. When using a stainless-steel brush, brush only in one direction. Take care to not brush too roughly: rough brushing can further imbed the oxides in the work piece. Also, use the brush only on aluminum work-don't clean aluminum with a brush that's been used on stainless or carbon steel. When using chemical etching solutions, make sure to remove them from the work before welding. To minimize the risk of hydrocarbons from oils or cutting solvents entering the weld, remove them with a degreaser. Check that the degreaser does not contain any hydrocarbons. Preheating: Preheating the aluminum workpiece can help avoid weld cracking. Preheating temperature should not exceed 230 F-use a temperature indicator to prevent overheating. In addition, placing tack welds at the beginning and end of the area to be welded will aid in the preheating effort. Welders should also preheat a thick piece of aluminum when welding it to a thin piece; if cold lapping occurs, try using run-on and run-off tabs. The push technique: With aluminum, pushing the gun away from the weld puddle rather than pulling it will result in better cleaning action, reduced weld contamination, and improved shielding-gas coverage.

Travel speed: Aluminum welding needs to be performed "hot and fast." Unlike steel, the high thermal conductivity of aluminum dictates use of hotter amperage and voltage settings and higher weld-travel speeds. If travel speed is too slow, the welder risks excessive burnthrough, particularly on thin-gage aluminum sheet. Shielding Gas: Argon, due to its good cleaning action and penetration profile, is the most common shielding gas used when welding aluminum. Welding 5XXXseries aluminum alloys, a shielding-gas mixture combining argon with helium - 75 percent helium maximum - will minimize the formation of magnesium oxide. Welding wire: Select an aluminum filler wire that has a melting temperature similar to the base material. The more the operator can narrow-down the melting range of the metal, the easier it will be to weld the alloy. Obtain wire that is 3/64or 1/16- inch diameter. The larger the wire diameter, the easier it feeds. To weld thin-gage material, an 0.035-inch diameter wire combined with a pulsed-welding procedure at a low wire-feed speed - 100 to 300 in./min - works well. Convex-shaped welds: In aluminum welding, crater cracking causes most failures. Cracking results from the high rate of thermal expansion of aluminum and the considerable contractions that occur as welds cool. The risk of cracking is greatest with concave craters, since the surface of the crater contracts and tears as it cools. Therefore, welders should build-up craters to form a convex or mound shape. As the weld cools, the convex shape of the crater will compensate for contraction forces. Power-source selection: When selecting a power source for GMAW of aluminum, first consider the method of transfer -spray-arc or pulse. Constant-current (cc) and constant-voltage (cv) machines can be used for sprayarc welding. Spray-arc takes a tiny stream of molten metal and sprays it across the arc from the electrode wire to the base material. For thick aluminum that requires welding current in excess of 350 A, cc produces optimum results. Pulse transfer is usually performed with an inverter power supply. Newer power supplies contain built-in pulsing procedures based on and filler-wire type and diameter. During pulsed GMAW, a droplet of filler metal transfers from the electrode to the workpiece during each pulse of current. This process produces positive droplet transfer and results in less spatter and faster follow speeds than does spray-transfer welding. Using the pulsed GMAW process on aluminum also better-controls heat input, easing out-of-position welding and allowing the operator to weld on thin-gage material at low wire-feed speeds and currents. Wire feeder: The preferred method for feeding soft aluminum wire long distances is the push-pull method, which employs an enclosed wire-feed cabinet to protect the wire from the environment. A constant-torque variable-speed motor in the wire-feed cabinet helps push and guide the wire through the gun at a constant force and speed. A high-torque motor in the welding gun pulls the wire through and keeps wire-feed speed and arc length consistent. In some shops, welders use the same wire feeders to deliver steel and aluminum wire. In this case, the use of plastic or Teflon liners will help ensure smooth, consistent aluminum-wire feeding. For guide tubes, use chisel-type outgoing and plastic incoming tubes to support the wire as close to the drive rolls as possible to prevent the wire from tangling. When welding, keep the gun cable as straight as possible to minimize wire-feed resistance. Check for proper alignment between drive rolls and guide tubes to prevent aluminum shaving.

Use drive rolls designed for aluminum. Set drive-roll tension to deliver an even wire-feed rate. Excessive tension will deform the wire and cause rough and erratic feeding; too-little tension results in uneven feeding. Both conditions can lead to an unstable arc and weld porosity. Welding guns: Use a separate gun liner for welding aluminum. To prevent wire chaffing, try to restrain both ends of the liner to eliminate gaps between the liner and the gas diffuser on the gun. Change liners often to minimize the potential for the abrasive aluminum oxide to cause wire-feeding problems. Use a contact tip approximately 0.015 inch larger than the diameter of the filler metal being used - as the tip heats, it will expand into an oval shape and possibly restrict wire feeding. Generally, when a welding current exceeds 200 A use a water-cooled gun to minimize heat buildup and reduce wire-feeding difficulties.

Frequently Asked Questions in Aluminum Welding

Frank Armao, Senior Application Engineer, The Lincoln Electric Company

Aluminum is being specified today in more and more applications because of its many advantages. Aluminum is lightweight (approximately 1/3 the weight of steel), has excellent electrical conductivity and better corrosion resistance properties than steel. As its growth accelerates, operators who are used to welding on steel, will need to learn the "ins and outs" of welding aluminum. Here are some of the most frequently asked questions that Lincoln Electric receives regarding the welding of aluminum and their answers from an expert:

1. 2. 3. 4. 5. 6. 7. 8.

Why is my aluminum weld much weaker than the parent material? What type of shielding gas should I use for aluminum welding? For TIG welding, what type of electrode is best for aluminum? How much preheat should I use when welding aluminum? What is the proper stress relieving practice for aluminum welds? How can I tell different aluminum alloys apart? How do I TIG weld two dissimilar thicknesses of aluminum? How do I weld 7075?

1. Why is my aluminum weld much weaker than the parent material? In steels a weld can be made as strong as the parent material, but this is not the case with aluminum. In almost all instances, the weld will be weaker than the parent material. To further understand why this occurs, let's look at the two classifications of aluminum alloys: heat treatable and non-heat treatable. The latter category is hardened only by cold working which causes physical changes in the metal. The more the alloy is cold worked the stronger it gets. But, when you weld an alloy that has been cold worked, you locally anneal the material around the weld so that it goes back to its 0 tempered (or annealed) condition and it becomes "soft". Therefore, the only time in the non-heat

treatable alloys that you can make a weld as strong as the parent material is when you start with 0 tempered material. With heat treatable aluminum alloys, the last heat treatment step heats the metal to approximately 400 F. But when welding, the material around the weld becomes much hotter than 400 F so the material tends to lose some of its mechanical properties. Therefore, if the operator doesn't perform post-weld heat treatments after welding, the area around the weld will become significantly weaker than the rest of the aluminum - by as much as 30 to 40 percent. If the operator does perform post weld heat treatments, the proprieties of a heat treatable aluminum alloy can be improved. The following is a guide as to which series of aluminum alloys are heat treatable and which are not: Heat treatable series: 2000, 6000, 7000. Non-heat treatable: 1000, 3000, 4000, 5000. 2. What type of shielding gas should I use for aluminum welding? For both TIG Welding (Gas Tungsten Arc Welding or GTAW) and MIG Welding (Gas Metal Arc Welding or GMAW) use pure argon for aluminum materials up to " in thickness. Above " in thickness, operators may add anywhere between 25 to 75 percent helium to make the arc hotter and increase weld penetration. Argon is best because it provides more cleaning action for the arc than helium does and it is also less expensive than helium. Never use any shielding gas that contains oxygen or carbon dioxide, as this will oxidize the aluminum. 3. For TIG Welding, what type of electrode is best for aluminum? For most materials, including steel, a two percent thoriated tungsten electrode is recommended, but since aluminum is welded with AC rather than DC, the electrical characteristics are different and the amount of energy put into the tungsten electrode is higher when AC welding. For these reasons, pure tungsten or zirconiated tungsten are recommended for aluminum welding. In addition, the electrode diameter for AC welding has to be significantly larger than when using DC. It is recommended to start with an electrode that is 1/8" and adjust as needed. Zirconiated tungsten can carry more current than pure tungsten electrodes. Another helpful hint for AC welding is to use a blunt tip - the arc tends to wander around a pointed tip. 4. How much preheat should I use when welding aluminum? While a little preheat is good, too much preheat can degrade the mechanical properties of the aluminum. As was discussed earlier, the last heat treatment for heat treatable alloys is 400 F so if the operator preheats the aluminum to 350 F and holds the temperature in that range while welding, the aluminum's mechanical properties are changed.

For the non-heat treatable alloys such as the 5000 series, if the operator holds the temperature even in the 200 F range - he or she can sensitize the material to stress corrosion cracking. In most cases, some preheat is acceptable to dry the moisture away from the piece, but preheat should be limited. Many inexperienced aluminum welders use preheat as a crutch. Since equipment for welding aluminum needs to operate at higher capacities, many feel that preheat helps eliminate equipment limitations, but this is not the case. Aluminum has a low melting point -- 1200 F compared to 2600 F to 2700 F for steel. Because of this low melting point, many operators think they only need light duty equipment to weld the aluminum. But, the thermal conductivity of aluminum is five times that of steel, which means that the heat dissipates very quickly. Therefore, welding currents and voltages for welding aluminum are higher than they are for steel so operators actually need heavier duty equipment for aluminum. 5. What is the proper stress relieving practice for aluminum welds? When welding, the operator sets up residual stresses around the vicinity of the weld because the molten material shrinks as it solidifies. Further, when the operator takes this welded structure and begins to remove material by machining, it tends to distort and create dimensional instability. To avoid this in aluminum, operators perform stress relieving by heating the material hot enough to allow the aluminum atoms to move around. For steel, the stress relieving temperature is approximately 1050 F to 1100 F, but for aluminum, the proper stress relieving temperature is 650 F. This means that in order for post weld stress relief on aluminum to be effective, the material will have to be heated to a temperature where mechanical properties will be lost. For this reason, post weld stress relief is not recommended for aluminum. 6. How can I tell different aluminum alloys apart? There are quite a few different aluminum alloys and for proper and safe welding, you should know what alloy your welding. If you don't, you can follow these general guidelines: Extrusions are generally 6000 series alloys Castings most often are a combination of aluminum/silicon cast -- some are weldable, others are not Pieces of sheet, plate or bar are probably 5000 to 6000 series alloys

If you want to be precise, purchase an alloy tester kit that will help you determine the exact makeup of your alloy. 7. How do I TIG weld two dissimilar thicknesses of aluminum? When an operator has two dissimilar thicknesses, he or she must set the parameters so that they are high enough to TIG weld the thickest piece. When welding, favor the joint and put more of the heat on the thicker piece.

8. How do I weld 7075? Most aluminum alloys are weldable, but there are a fair number of them that are not, including 7075 aluminum. The reason 7075 is singled out in this example is that it is one of the highest strength aluminum alloys. When designers and welders look for an aluminum alloy to use, many will start by reviewing a table that lists all of the aluminum alloys and their strengths. But what those newcomers don't realize is that few of the higher strength aluminum alloys are weldable - especially those in the 7000 and 2000 series - and they should not be used. The one exception to the rule of never using 7075 for welding is in the injection molding industry. This industry will repair dies by welding 7075 - but it should never be used for structural work. Here are some simple guidelines to follow when choosing aluminum alloys:

Alloy Series 1000 series 2000 series

Main Alloying Elements Pure aluminum Aluminum and copper. (High strength aluminum used in the aerospace industry ) Aluminum and manganese. (Low- to mediumstrength alloys, examples of products using these alloys are beverage cans and refrigeration tubing) Aluminum and silicon. (Most alloys in this series are either welding or brazing filler materials) Aluminum and magnesium. (These alloys are used primarily for structural applications in sheet or plate metals - all 5000 series alloys are weldable ) Aluminum, magnesium and silicon. (These alloys are heat treatable and commonly used for extrusions, sheet and plate - all are weldable, but can be crack sensitive. Never try to weld these alloys without using filler metal) Aluminum and zinc. (These are high strength aerospace alloys that may have other alloying elements added)

3000 series

4000 series 5000 series

6000 series

7000 series

Lincoln suggests that if you have a need to design something of high strength aluminum, look to a 5000 series high magnesium alloy instead of a 2000 or 7000 series. The 5000 series alloys are weldable and will produce the best results. Conclusion: Lincoln Electric offers a full range of aluminum solutions from power sources, such as the Power Wave 455M, that are custom designed to perform with optimal arc characteristics on aluminum, to wire feeders, such as the Cobramatic push-pull system, for optimizing the feeding of the soft aluminum wire, to premium SuperGlaze aluminum wire, made with consistent chemistry for consistent performance. In addition to products, Lincoln prides itself on being

an aluminum welding expert and can be reached by either phone 1-888-9353877 or e-mail to answer your questions. CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customers particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products. Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Weldability of materials

Aluminium alloys
Aluminium and its alloys are used in fabrications because of their low weight, good corrosion resistance and weldability. Although normally low strength, some of the more complex alloys can have mechanical properties equivalent to steels. The various types of aluminium alloy are identified and guidance is given on fabricating components without impairing corrosion and mechanical properties of the material or introducing imperfections into the weld.

Material types
As pure aluminium is relatively soft, small amounts of alloying elements are added to produce a range of mechanical properties. The alloys are grouped according to the principal alloying elements, Specific commercial alloys have a four-digit designation according to the international specifications for wrought alloys or the ISO alpha - numeric system. The alloys can be further classified according to the means by which the alloying elements develop mechanical properties, non-heat-treatable or heattreatable alloys.

Non-heat-treatable alloys
Material strength depends on the effect of work hardening and solid solution hardening of alloy elements such as magnesium, and manganese; the alloying elements are mainly found in the 1xxx, 3xxx and 5xxx series of alloys. When welded, these alloys may lose the effects of work hardening which results in softening of the HAZ adjacent to the weld.

Heat-treatable alloys
Material hardness and strength depend on alloy composition and heat treatment (solution heat treatment and quenching followed by either natural or artificial ageing produces a fine dispersion of the alloying constituents). Principal alloying elements are defined in the 2xxx, 6xxx and 7xxx series. Fusion welding redistributes the hardening constituents in the HAZ which locally reduces material strength.

Most of the wrought grades in the 1xxx, 3xxx, 5xxx, 6xxx and medium strength 7xxx (e.g. 7020) series can be fusion welded using TIG, MIG and oxyfuel processes. The 5xxx series alloys, in particular, have excellent weldability. High strength alloys (e.g. 7010 and 7050) and most of the 2xxx series are not recommended for fusion welding because they are prone to liquation and solidification cracking. The technique of Friction Stir Welding is particularly suited to aluminium alloys. It is capable of producing sound welds in many alloys, including those heat treatable alloys which are prone to hot cracking during fusion welding.

Filler alloys
Filler metal composition is determined by:

weldability of the parent metal minimum mechanical properties of the weld metal corrosion resistance anodic coating requirements

Nominally matching filler metals are often employed for non-heat-treatable alloys. However, for alloy-lean materials and heat-treatable alloys, nonmatching fillers are used to prevent solidification cracking. The choice of filler metal composition for the various weldable alloys is specified in BS EN 1011 Pt 4:2000 for TIG and MIG welding; recommended filler metal compositions for the more commonly used alloys are given in the Table.

Alloy Designation

Chemical Designation

Classification Filler R1080A R-3103 R5556A R-5356 -

Application Chemical plant Buildings, heat exchangers Filler wire/rod Ships, rail wagons, bridges Road vehicles, marine Filler wire/rod

EN AW-1080A EN AW-Al 99.8(A) NHT EN AW-3103 EN AW-Al Mn1 NHT NHT NHT -

EN AW-4043A EN AW-Al Si5(A) EN AW-5083 EN AW-5251 EN AW-5356 EN AW-Al Mg4.5Mn0.7 EN AW-Al Mg2Mn0.3 EN AW-Al Mg5Cr(A)

EN AW-5556A EN AW-Al Mg5Mn EN AW-6061 EN AW-Al Mg1SiCu EN AW-Al Zn4.5Mg1

HT

R4043A R-5356 R5556A

Filer wire/rod Structural, pipes

EN AW-7020

HT

Structural, transport

HT = Heat treatable, NHT = Non Heat treatable

Imperfections in welds
Aluminium and its alloys can be readily welded providing appropriate precautions are taken. The most likely imperfections in fusion welds are:

porosity cracking poor weld bead profile

Porosity
Porosity is often regarded as an inherent feature of MIG welds; typical appearance of finely distributed porosity in a TIG weld is shown in the photograph. The main cause of porosity is absorption of hydrogen in the weld pool which forms discrete pores in the solidifying weld metal. The most common sources of hydrogen are hydrocarbons and moisture from contaminants on the parent material and filler wire surfaces, and water vapour from the shielding gas atmosphere. Even trace levels of hydrogen may exceed the threshold concentration required to nucleate bubbles in the weld pool, aluminium being one of the metals most susceptible to porosity. To minimise the risk, rigorous cleaning of material surface and filler wire should be carried out. Three cleaning techniques are suitable; mechanical cleaning, solvent degreasing and chemical etch cleaning. Mechanical cleaning Wire brushing (stainless steel bristles), scraping or filing can be used to remove surface oxide and contaminants. Degreasing should be carried out before mechanical cleaning. Solvents

Dipping, spraying or wiping with organic solvents can be used to remove grease, oil, dirt and loose particles. Chemical etching A solution of 5% sodium hydroxide can be used for batch cleaning but this should be followed by rinsing in HNO and water to remove reaction products on the surface.
3

In gas shielded welding, air entrainment should be avoided by making sure there is an efficient gas shield and the arc is protected from draughts. Precautions should also be taken to avoid water vapour pickup from gas lines and welding equipment; it is recommended that the welding system is purged for about an hour before use.

Solidification cracks
Cracking occurs in aluminium alloys because of high stresses generated across the weld due to the high thermal expansion ( twice that of steel) and the substantial contraction on solidification typically 5 % more than in equivalent steel welds. Solidification cracks form in the centre of the weld,, usually extending along the centreline during solidification. Solidification cracks also occur in the weld crater at the end of the welding operation. The main causes of solidification cracks are as follows:

incorrect filler wire/parent metal combination incorrect weld geometry welding under high restraint conditions

The cracking risk can be reduced by using a non-matching, crack-resistant filler (usually from the 4xxx and 5xxx series alloys). The disadvantage is that the resulting weld metal may have a lower strength than the parent metal and not respond to a subsequent heat treatment. The weld bead must be thick enough to withstand contraction stresses. Also, the degree of restraint on the weld can be minimised by using correct edge preparation, accurate joint set up and correct weld sequence.

Liquation cracking
Liquation cracking occurs in the HAZ, when low melting point films are formed at the grain boundaries. These cannot withstand the contraction

stresses generated when the weld metal solidifies and cools. Heat treatable alloys, particularly 6xxx and 7xxx series alloys, are more susceptible to this type of cracking. The risk can be reduced by using a filler metal with a lower melting temperature than the parent metal, for example the 6xxx series alloys are welded with a 4xxx filler metal. However, 4xxx filler metal should not be used to weld high magnesium alloys (such as 5083) as excessive magnesiumsilicide may form at the fusion boundary decreasing ductility and increasing crack sensitivity.

Poor weld bead profile

Incorrect welding parameter settings or poor welder technique can introduce weld profile imperfections such as lack of fusion, lack of penetration and undercut. The high thermal conductivity of aluminium and the rapidly solidifying weld pool make these alloys particularly susceptible to profile imperfections.