Call Us - Alphaweld(08) 9456 8000

Shopping Cart

Cart: 0 items
Total: $0.00 excl GST

A Quick Guide to Aluminium MIG/TIG Welding

Date: 26-07-2021
Welding Aluminium

Quick Guide to Aluminium MIG/TIG Welding

 

While traditional choices like steel and stainless remain by far the more common materials used in welding jobs, in recent years, aluminium has been gaining popularity for a growing number of applications. Favoured by some welders for being lightweight and non-corrosive, it is in many ways ideal for the automotive and airline construction industries. It is also widely known to present some unique challenges.

In this blog, we take a look at the difficulties inherent in aluminium welding and the solutions used to combat them. We also present some of the welding tools and equipment commonly used in aluminium welding applications.

 

The Challenges of Welding with Aluminium 

Aluminium is a soft metal with a tough, oxidized external layer. The internal layer melts at 660°C – much lower than steel’s 1425°-1540° – but its outer layer melts at around 2038°. This disparity creates problems during welding. In its molten state, it becomes highly susceptible to impurities, often resulting in porous, low-quality welds. As aluminium is less stronger than steel, this tendency makes it even less reliable and durable for heavy-duty welding jobs.

In addition to this, aluminium has a much smaller window in which it remains workable while heated, and it lacks the kinds of visual cues that welders can usually rely on when working with steel or copper.
 

The Solutions 

Over the years, the welding industry has developed a number of ways to mitigate the problematic qualities of aluminium as a welding material. To combat the problem of aluminium’s relative weakness, it is usually alloyed with other metals such as copper, magnesium, zinc, and tin. This makes the joins stronger and more durable, though aluminum alloy welds will still have lower fatigue limits than steel and are generally not found in high fatigue-tolerance applications.
 

Our Aluminium Welding Range

At Alphaweld, we stock a premium range of aluminium welding consumables from Betaweld. Betaweld’s aluminum MIG wire is bolstered with a combination of other metals to improve its durability and tensile abilities. It is also manufactured in larger diameters to create a smoother feed, resulting in better arc control and smoother finishes.
 

Aluminium Finishing Tools

Aluminium’s high sensitivity and low melting temperature can also make it difficult to properly cut and grind to achieve a smooth finish. Alphaweld’s range of high-quality abrasive discs from Klingspor offer consistent contact while generating low heat, resulting in clean, professional finishes.
 

Stainless Steel Brushes

One common way of improving the weld quality when working with an aluminium workpiece is to remove the tough outer layer of oxide. This is best achieved using a stainless steel wire brush attached to an angle grinder. Alphaweld offers a variety of cup- and bevel-brushes from brands like Taipan and Josco. This is not only effective as a method or surface preparation, but can also be used to create a uniform, brushed-metal finish after the weld has been completed.

Why Buy from Alphaweld?

Alphaweld has built a reputation for providing Australian welding professionals with a comprehensive and innovative range of welding products at competitive prices. We offer same-day despatch on all orders of stocked items made before 2.00pm and offer a 100% guarantee on all our products.
 

Contact Alphaweld Today

Visit the Alphaweld website for an extensive range of aluminium welding products or if you would like to speak to one of our expert team members, please contact us.