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Kevin Lyttle Senior Development Associate Praxair, Inc. Garth Stapon Marketing Manager Metal Fabrication Praxair, Inc.
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Reprinted from Practical Welding Today January/February 1999

Equipment and procedures for welding

Facing the challenge with the right methods and supplies
By Garth Stapon and Kevin Lyttle of aluminum is substantially greater than that of mild steel, which creates a welding challenge. Because the radiant heat energy from the electric arc or flame is rapidly conducted away from the weld joint, increased heat energy is required as the base metal thickness inch. This increased increases beyond 18 energy can be gained via a larger tip with an oxyfuel process or a largerdiameter tungsten electrode with gas tungsten arc welding (GTAW). While a contaminant-free area is important for carbon steel welding operations, it is essential for aluminum welding. The base material must be clean if a high-quality weld is to be achieved. Degreasing before the start of the welding operation is recommended to limit a potential source of hydrogen, which is the chief cause of porosity in aluminum welds. However, certain degreasers may react with arc radiation and form potentially harmful by-products, so their material safety data sheets (MSDSs) should be consulted for decomposition information. Removal of aluminum oxide also is recommended to help improve weld deposit cleanliness, increase travel speed, and reduce weld metal porosity. One typical low-cost removal method is to scrub the oxide off with a simple stainless steel brush. This type of brush, and any other surface preparation tools, should be dedicated exclusively to the aluminum fabrication operation, regardless of the alloy being joined. This is critical to preventing weld contamination. Iron particles remaining on a grinding wheel or a wire brush from steel work can be transferred to and imbedded into an aluminum plate by those tools. These particles will rust and be readily noticeable once the fabricated aluminum component goes into service. Particles as minute as sparks from grinding can adversely impact the appearance of the completed aluminum structure and create a major rework problem. During the direct current electrode positive (DCEP) operation of either the gas metal arc welding (GMAW) or GTAW, gas ion bombardment of the aluminum surface breaks up oxide on that surface. This cleaning action improves wetability and decreases the presence of contaminants that can cause porosity. The use of alternating current high frequency (ACHF) power for GTAW combines the cleaning action of the DCEP cycle with the better arc stability and penetration of the direct current electrode negative (DCEN) cycle. Balancing the two portions of the ACHF cycle leads to optimal control and quality for GTAW of aluminum. The cleaning action also can be enhanced by the choice of the shielding gasas the argon content of the shielding gas is increased, the cleaning action is improved.

nowledge of aluminum joining can be a fabricating companys ticket to increased growth and profitability. Market trends, including government regulations such as Corporate Average Fuel Economy (CAFE) in the automotive industry, are driving the expanded use of lightweight aluminum and aluminum alloys in many industries. Although aluminum is generally considered to be difficult to weld, with the proper precautions and procedures, high-quality results can be the reward. Procedures typically used in mild steel fabrication must be significantly modified to achieve high-quality, defect-free results when joining aluminum alloys. This article discusses several factors that impact the quality of aluminum welds.

Base Metal
Pure aluminum is a ductile, lightweight, low-strength material with a low melting point (1,220 degrees Fahrenheit). It also has a tenacious refractory oxide layer that must be removed from the surfaces to be joined because the oxides melting point is greater than that of the base metal. When alloyed with copper, magnesium, silicon, or a variety of other materials, aluminum can be made responsive to heat treatment and up to six times stronger when compared with 1100 series alloys. The ultimate tensile strength of the commonly welded alloys is in the range of 30,000 to 40,000 pounds per square inch (PSI). The electrical and heat conductivity

Shielding Gas
Pure argon is the most widely used shielding gas for both GTAW and GMAW of aluminum. To ensure highquality welds with minimum porosity, gas purity should be at least 99.995 percent. The gas hoses and delivery system should be free of leaks and designed for use in argon service. Most quality issues related to contaminated shielding gas arise from a leak in the supply system. Helium is often mixed with argon to increase the thermal conductivity of the

Suggested Filler Metals for Commonly Welded Aluminum Alloys for Desired Characteristics
Recommended Filler Metal For:
Base Metal
1100 2219 3303 5052 5083 5086 5454 5456 6061 6063 7005 7039

High Strength
4043 2319 4043 5356 5183 5356 5356 5556 5356 5356 5556 5556

Good Ductility
1100 2319 1100 5654 5356 5356 5554 5356 5356 5356 5356 5356

Color Match after Anodizing

1100 2319 1100 5356 5183 5356 5554 5556 5654 5356 5356 5356

Salt Water Corrosion Resistance

1100 2319 1100 5554 5183 5356 5554 5556 4043 4043 5356 5356

Least Cracking Tendency

4043 2319 4043 5356 5356 5356 5356 5356 4043 4043 5356 5356

Figure 1
Selection of a filler alloy for a specific application depends on a number of criteria, including strength and ductility. shielding gas. This helps to increase arc energy and is suitable for welding aluminum and aluminum alloys greater than 1 8 inch thick. In GMAW, a change from argon to an argon-helium mixture causes an increase in arc voltage, and the shielding gas flow rate must be increased slightly to maintain a stable, spatter-free arc. Travel speed, penetration, and productivity are generally enhanced by a switch to a two-gas blend. In GTAW, the use of an argon-helium blend can make a 250-amp power supply perform like a higher-current model used with pure argon shielding, preventing the need to upgrade the equipment when working with thicker (greater than 38 inch) aluminum alloys. The increased heat input is generated by the higher arc voltage needed for the helium component of the shielding gas. of needs. The two most widely used alloys are 4043, which contains silicon to improve puddle fluidity; and 5356, which is alloyed with magnesium for greater strength. Selection of a filler alloy for a specific application depends on a number of criteria (see Figure 1): 1. Weld bead cracking tendency 2. Strength 3. Ductility 4. Corrosion resistance 5. Color match (after anodizing) Each aluminum alloy series has a different sensitivity for weld cracking. Cracking is generally a result of low strength or ductility in the weld metal at elevated temperatures. A filler metal with a melting temperature similar to or below that of the base material reduces the tendency for intergranular cracking in the heataffected zone (HAZ). In general, as the alloy content of the weld deposit increases, the cracking tendency decreases. For a parent metal prone to cracking, a filler wire that is outside of its crack sensitivity zone should be selected. For strength, an alloy (typically 5000 series) should be chosen that meets the

minimum tensile requirements. The final selection is based on the properties produced as well as the availability of the filler wire. For ductility requirements, alloy selection is typically based on availability and other desired wire characteristics. Manufacturers literature can be reviewed to determine compatibility between the filler metal and the base metal, also considering any postweld heat treatment that may be required. Corrosion resistance is another selection criterion. While aluminum is generally considered to be corrosion-resistant, the best performance will be given by a weld metal with a chemistry closely matching that of the base material. If anodic coatings (anodizing) will be applied after welding, color match between the base metal and the weld metal is usually important. Here, again, if the base metal and weld metal are of similar chemistries, less difference will be visible. Filler metals with magnesium alloying (5000 series) generally work well; silicon-containing alloys (such as 4043) will darken after anodizing.

Feed System
With GMAW, the electrode diameter should be selected based on the material thickness and the feed system being used. Because GMAW is the most widely used welding technique for aluminum, a number of equipment options are available. The feed system options can be classified into three broad categories: 1. Push systems with large spools 2. Push systems with small spools 3. Push-pull systems with large spools Push Systems Large Spool. Most mild steel wire feeders are of the push type. These systems can be used to join aluminum base material thicker than 18 inch. With a higher-tensile (5356), largerdiameter (greater than 0.045 inch) wire, it is possible to feed the wire reliably, providing necessary changes to the conduit liner, drive rolls, and contact tip are made. Conduit and gun lengths should be kept to a minimum (6 to 10 feet), and the gun should be water-cooled, if possible.

Filler Metal
As with most welding processes, the filler metal used should closely match the properties of the aluminum base material. Because aluminum is available in numerous grades, many filler metals have been developed to meet a variety

Push systems are typically used with three-phase, constant-voltage (CV) power. Weld penetration can be improved through the use of steep slope (if available from the power supply), but arc starts may be less consistent compared with the use of flat slope. If the application involves frequent starts and stops, flat slope should be selected. A 116-inch-diameter wire provides better feedability, but care should be taken to avoid overwelding caused by the larger wire size and operating current level. Push Systems Small Spool. A spool-on gun is usually paired with a simplified GMAW system using a 250amp, single-phase, constant-voltage power supply. Duty cycle is usually rated at 40 to 50 percent. Arc starting and welding penetration can sometimes be improved by using a three-phase power supply instead of a single-phase system. The gun contains feed rolls that push the aluminum wire a short distance (usually 1 foot) from a self-contained 1-pound spool. A two-step trigger permits gas flow before the welding operation begins. The arc is initiated in an inert atmosphere, which helps enhance welding quality. These systems are suitable for feeding small-diameter (0.030 to 0.047 inch) and low-tensile wires (such as 4043). Although the 1-pound spool gun is good for occasional work, the additional weight of the gun and its limited access in confined spaces can reduce its suitability in some fabrication operations. It is a lower-cost option, but issues such as welder fatigue, filler material cost, and frequent spool changeouts make it less suited for use in production welding applications. Push-Pull Systems. Push-pull systems are more suitable for production welding. On systems that have drive rolls inside the gun, independent front and rear drive roll speed controls can allow for a greater amount of pulling action. The drive roll located at the feeder can then act as a slave to lessen the possibility for wire feed problems. With some push-pull systems, the user can switch from constant current

Air contaminants in the form of solid particulate matter and various gases are an unavoidable by-product of any arc welding process.
(CC) to CV power supply. This capability is helpful when welding thicker base inch), because the CC sysmetals (>12 tem can sometimes offer better welding penetration than can a CV unit. Additional options to consider include a slow run-in speed for better arc starting, an enclosed cabinet for wire storage, and a sensitive brake system to prevent wire overrun in production welding applications. The wire conduit length of pushpull systems is typically 25 to 50 feet, and the gun typically weighs less than 2 pounds. For high-duty-cycle production welding, the use of a water-cooled gun is recommended.

be set at a minimum level while controlling wire overrun at arc stops.

Pulsed GMAW
In most GMAW applications using DCEP power, the filler metal is transferred across the arc as a stream of fine, superheated droplets (spray transfer) when the welding current and voltage are above the minimum transition level. This level is a function of electrode size and composition and is also influenced by the type of shielding gas selected. Spray welding is typically performed in flat or downhand positions. Pulsed spray is a modification of conventional spray and can be used for welding in all positions. Here, metal transfer takes place during high-current peaks. A low current is supplied to keep the arc on during the off-peak periods. This action reduces the overall heat input to the base metal and produces good weld puddle and penetration control especially for out-of-position welding or thin materials. This lower heat input makes it easier to weld thin aluminum sections using larger-diameter wires while still maintaining a low-spatter spray metal transfer.

Recommended Equipment Practices

The columnar strength of aluminum wire is much lower than that of its mild steel counterpart. To help ensure good feeding and consistent wire performance, the following methods and features can be used on any system: 1. The drive roll should be polished to a very smooth surface with a stainless steel brush to remove any burrs or rough edges. The factory finish as delivered is generally not acceptable. A U-groove drive roll can help reduce the tendency to flatten or crush the wire. Drive roll tension should be set at the lowest possible level to achieve consistent feeding. 2. The GMAW gun should be kept as straight as possible during welding. 3. The feeding distance should be kept as short as possible, unless a pushpull system is employed. 4. An oversized contact tip (0.002 to 0.005 inch larger than the wire diameter selected) can help improve feedability and current pickup. 5. When a large wire spool is used, the tension on the spool spindle should

Fumes and Gases in Aluminum Welding

Air contaminants in the form of solid particulate matter (fumes) and various gases are an unavoidable by-product of any arc welding process. The heat and ultraviolet radiation emitted from the arc generate varying quantities of these contaminants, depending on operating conditions and the composition of the filler material and shielding gas. For aluminum, the major constituent of the fume is aluminum oxide. Additional components include some small amounts of complex particles containing aluminum-copper, aluminum-magnesium, and other aluminum alloys (depending on the filler material used). At present, the accepted exposure guideline for aluminum welding fume is the same as that for total welding fume of any type (5 mg/m3). Health effects studies concerning exposure to aluminum are continuing.

While no conclusive evidence exists at this time to support a reduction in the exposure limit, care should be taken to maintain exposures as low as possible and to have measurements taken and evaluated by qualified safety/health professionals. Among the more predominant gases produced during welding is ozone. Ozone is unique among contaminant gases because it is formed not by thermal or chemical reactions, but by the action of a specific wavelength band of ultraviolet (UV) on oxygen molecules in the arc environment. Ozone-creating radiation is found in arcs shielded with argon and in vapor forms of metallic elements, such as silicon. Welding variablessuch as voltage and current, as it influences the type of metal transferand the total welding fume level also affect the generation of ozone-forming UV radiation. In aluminum welding, higher levels

of ozone may be present during the use of silicon-alloyed filler alloys such as 4043, and when 100 percent argon is used for shielding. The use of magnesium-containing wires (5000 series) and helium in the shielding gas will reduce the amount of ozone generated. Because many variables that affect ozone generation may be unique to a specific welding application, welders should be aware of potential ozone exposure and have measurements taken and evaluated by qualified safety/health professionals.

The Economics of an Informed Choice

The economics of process selection for aluminum welding includes the cost of equipment, labor, consumable materials, and related operations such as plate preparation and postweld finishing. For industrialized nations, typically 80 to 85 percent of the total welding cost is attributed to labor, 10 to 15 per-

cent to consumables, and the balance to equipment and electrical power. Therefore, a 10 percent reduction in labor costs will generate more savings than the same reduction in consumables cost. The proper selection and use of shielding gas, wire, and equipment can reduce labor costs by increasing welding speed and duty cycle while minimizing postweld cleanup time. G Garth Stapon is Marketing Manager Metal Fabrication, and Kevin Lyttle is Senior Development Associate for Praxair Inc., 39 Old Ridgebury Road, Danbury, Connecticut 06810-5113, phone 1-800PRAXAIR or 716-879-4077, fax 1-800772-9985 or 716-879-2040. Praxair, Inc., produces, sells, and distributes atmospheric, process, and specialty gases and high-performance surface coatings. Photo courtesy of the Lincoln Electric Company, Cleveland, Ohio.

WORLD HEADQUARTERS Praxair, Inc. 39 Old Ridgebury Road Danbury, CT 06810-5113 Tel: 1-800-PRAXAIR (1-800-772-9247) (716) 879-4077 Fax: 1-800-772-9985 (716) 879-2040

For more information, or a more detailed listing of Praxairs international locations, visit our Web site. Internet: www.praxair.com e-mail: info@praxair.com

The information contained herein is offered for use by technically qualified personnel at their discretion and risk, without warranty of any kind. PRAXAIR and the FLOWING AIRSTREAM design are either trademarks or registered trademarks of Praxair Technology, Inc. in the United States and/or other countries. Copyright 1999, Praxair Technology, Inc. All Rights Reserved.

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