Page 30 - MetalForming March 2014

Troubleshooting Mig Welding of Aluminum
Follow the guidelines offered here to prevent weld cracking, porosity and discoloration, and avoid wire-feeding problems when welding aluminum.
BY GALEN WHITE
Aluminum offers numerous ben- efits to OEMs—high strength- to-weight ratio, corrosion resist- ance and high thermal and electrical conductivity—that make it one of the most specified materials in the welding industry. However, welding with alu- minum presents some unique chal- lenges to fabricators, including a tena- cious oxide layer, vastly different compositions among alloys, the need to use a less rigid filler metal, and the need for very clean base metal. Select- ing the right type of welding filler metal, consumables and equipment, as well as quick troubleshooting, can help miti- gate these issues.
To minimize downtime and enhance productivity in the weld shop, this arti- cle looks at some of the most common issues welding operators face when gas-metal-arc welding (GMAW, mig) aluminum. We also discuss tips to pre- vent those problems, or to quickly address them if they occur.
Galen White is senior welding engineer, Hobart Brothers Company, Troy, OH: 937/332-4000; www.hobartbrothers.com
Welding aluminum presents some unique challenges. Take care to select the right type of filler metal, consumables and equipment, and take steps to ensure quick trouble- shooting of any problems that arise.
28 MetalForming/March 2014
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