Aluminum Welding Techniques

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    Aluminum WeldingTechniques

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    Aluminium and its alloys

    Abundant metal (8% of earthscrust).

    Light weight.

    Moderate to high strength(depending on alloy).

    High conductivity.

    Corrosion resistant (Al2O3 coating).

    Non-magnetic.

    Good reflector.

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    The wrought alloy designation system isbased on a 4 digit designation xxxx

    1XXX - Pure Al (99.0%+)

    2XXX - Al + Copper.

    3XXX - Al + Manganese.

    4XXX - Al + Silicon.

    5XXX - Al + Magnesium.

    6XXX - Al + Magnesium and Silicon.7XXX - Al + Zinc.

    8XXX - Al + Other Elements.

    Wrought Alloy Designation

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    The first digit (Xxxx) indicates theprincipal alloying element.

    The second single digit (xXxx), if

    different from 0, indicates a modificationof the specific alloy.

    The third and fourth digits (xxXX) are

    arbitrary numbers given to identify aspecific alloy in the series.

    Wrought Alloy Designation

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    CAST ALLOY DESIGNATION

    The cast alloy designation system is based on a 3digit-plus decimal designation xxx.x (i.e. 356.0).

    1XX.X - Pure Al (99.0%+)

    2XX.X - Al + Copper.

    3XX.X - Al + Copper Plus Silicon.

    4XX.X - Al + Silicon.

    5XX.X - Al + Magnesium.

    6XX.X - Al + Magnesium Plus Silicon.

    7XX.X - Al + Zinc.

    8XX.X - Al + Tin.

    9XX.X - Al + Other elements.

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    CAST ALLOY DESIGNATION

    The first digit (Xxx.x) indicates theprincipal alloying element.

    The second and third digits (xXX.x)are arbitrary numbers given toidentify a specific alloy in the series.

    The number following the decimalpoint indicates whether the alloy is acasting (.0) or an ingot (.1 or .2).

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    TEMPER DESIGNATION

    The 1xxx, 3xxx, and 5xxx series are

    strain hardenablestrain hardenable only.

    The 2xxx, 6xxx, and 7xxx series are

    heat treatableheat treatable.The 4xxx series consist of both heatheat

    treatable and nontreatable and non--heat treatableheat treatable alloys.

    The 2xx.x, 3xx.x, 4xx.x and 7xx.xseries are heat treatableheat treatable.

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    TEMPER DESIGNATION

    Basic Designations

    F - As Fabricated

    O - AnnealedH - Strain Hardened

    W - Solution Heat Treated

    T - Thermally Treated

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    As FabricatedAs Fabricated

    Applies to products of aforming process in which no

    special control over thermalor strain hardening conditions

    is employed.

    TEMPER DESIGNATION

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    TEMPER DESIGNATION

    AnnealedAnnealed

    Applies to product which hasbeen heated to produce the

    lowest strength condition toimprove ductility and

    dimensional stability

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    TEMPER DESIGNATION

    Strain HardenedStrain Hardened

    Applies to products that are

    strengthened through cold-working. The strain hardening

    may be followed by

    supplementary thermal

    treatment, which produces

    some reduction in strength.

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    TEMPER DESIGNATION

    Solution Heat TreatedSolution Heat Treated

    A process of heating the alloyto an elevated temperature

    (990F) in order to put the

    alloying elements or

    compounds into solution.

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    TEMPER DESIGNATION

    Thermally TreatedThermally Treated

    Applies to product that hasbeen heat-treated,sometimes with

    supplementary strain-hardening, to produce astable temper.

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    TEMPER DESIGNATION

    AgingAgingThe precipitation of aportion of the elements orcompounds from asupersaturated solution in

    order to yield desirableproperties.

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    SUBDIVISIONS OFHTEMPER

    STRAIN HARDENEDThe first digit after the H indicates abasic operation:

    H1 -

    Strain Hardened Only.H2 - Strain Hardened and PartiallyAnnealed.

    H3 - Strain Hardened andStabilized.

    H4 - Strain Hardened andLacquered.

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    SUBDIVISIONS OFTTEMPER

    THERMALLY TREATED

    T1 - Air Cool and Natural Aged.

    T2 - Air Cool, Cold Worked and Natural

    Aged.

    T3 - Solution, Cool, ColdWorked and

    Natural Aged.

    T4 - Solution, Cool and Natural Aged.

    T5 - Air Cool and Artificially Aged.

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    SUBDIVISIONS OFTTEMPER

    THERMALLY TREATED

    T6 - Solution, Water Cool and Artificial Aged.

    T7 - Solution, Water Cool and Over Aged.

    T8 - Solution, Water Cool, Cold Worked and

    Aged.

    T9 - Solution, Water Cool, Aged and Cold

    Worked.

    T10 - Air Cool, ColdWorked and ArtificialAged.

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    ALUMINUM ALLOYS AND

    THEIR CHARACTERISTICS11xxx Series Alloys (Nonxxx Series Alloys (Non--heat treatable)heat treatable)

    Pure Aluminium

    9999..00% minimum aluminum.% minimum aluminum.

    Excellent corrosion resistance.Relatively poor mechanical properties.

    Excellent electrical and thermalconductivity.

    Food, chemical, heat exchangers,electrical wiring, capacitor foil.

    Weldable.

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    ALUMINUM ALLOYS AND

    THEIR CHARACTERISTICS22xxx Series Alloys (Heat treatable)xxx Series Alloys (Heat treatable)

    Aluminum/Copper alloys.

    Copper additions ranging from 0.7 to 6.8%

    Precipitation hardened.

    Excellent strength over a wide range of

    temperature.

    Aircraft structure and mechanicalcomponents, vehicle body panels.

    Weldability poor to fair depending on

    alloy.

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    ALUMINUM ALLOYS AND

    THEIR CHARACTERISTICS

    33xxx Series Alloysxxx Series Alloys (Non(Non--heat treatable)heat treatable)

    Aluminum/manganese alloys

    Manganese additions ranging fromManganese additions ranging from 00..0505 toto 11..88%%Excellent formability and

    weldability.

    Very high corrosion resistance.Cans, chemical vessels, industrial

    roofing, culvert pipe.

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    ALUMINUM ALLOYS AND

    THEIR CHARACTERISTICS

    44xxx Series Alloysxxx Series Alloys

    (Heat treatable & non(Heat treatable & non--heat treatable)heat treatable)

    Aluminum/silicon alloys

    Silicon additions ranging from 0.6 to 21.5%Effective Liquidus Suppressant.

    Good Wear Property - Cast Alloys.

    Inferior corrosion resistance.High temperature parts, pistons.

    Weldable.

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    ALUMINUM ALLOYS AND

    THEIR CHARACTERISTICS55xxx Series Alloysxxx Series Alloys (Non(Non--heat treatable)heat treatable)

    Aluminum/magnesium alloysMagnesium additions ranging from 0.2 to 6.2%

    Moderate strength.Good corrosion resistance.

    Excellent weldability.

    Shipbuilding, transportation,pressure vessels, bridges andbuildings.

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    ALUMINUM ALLOYS AND

    THEIR CHARACTERISTICS66xxx Series Alloysxxx Series Alloys (Heat treatable)(Heat treatable)Aluminum/magnesium-silicon alloys

    magnesium and silicon additions of around 1.0%

    Easily workable.

    Excellent strength.

    Excellent corrosion resistance.

    Limited to excellent weldability.

    Pressure vessels, cryogenics,Communication towers, Armour plate,

    Marine, auto and aircraft applications.

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    ALUMINUM ALLOYS AND

    THEIR CHARACTERISTICS77xxx Series Alloysxxx Series Alloys (Heat treatable)(Heat treatable)Aluminum/zinc alloys

    Zinc additions ranging from 0.8 to 12.0%

    Highest strength aluminum alloys.

    Used where stress corrosion is a problem.

    Alloys with Cu can be precipitation hardened.

    Unweldable to excellent weldabilitydepending on alloy and process.

    Aircraft, aerospace, and competitive sporting

    equipment.

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    WELDING ALUMINUM ALLOYS

    Aluminum Welding DifficultiesAluminum oxide surface coating.

    Al2O3.High thermal conductivity.

    Three to five times as fast as steel

    High thermal expansion coefficient.2X Steel& welds decrease about 6% in volume

    when solidifying.

    Low melting temperature.

    Absence of color change as temperatureapproaches the melting point.

    Prone to contamination by O2, N2, H2.Solidification cracking, particularly of many heat

    treatable alloys.

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    WELDING ALUMINUM ALLOYS

    Cleaning

    Solvent cleaner, mechanical,

    etching.Weld pre-cleaning

    Mechanical methods plus solvent

    wipe

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    FI I

    Avoidance of cracking.

    Tensile strength of weld.

    Weld ductility.Service temperature.

    Corrosion resistance.Colour match after anodising.

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    Solidification cracking

    Use matching filler for strain-hardenedgrades

    Dont mix 4000 series and 5000 seriesalloys (Mg2Si eutectics formed)

    Dont mix 5000 series and 2000 seriesalloys

    Many heat treatable grades are hotshort

    No autogenous welding

    Avoid high dilution

    Medium copper grades are Unweldable

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    HAZ cracking

    Liquation cracking can occur in the

    HAZ of age hardenable grades

    Keep arc energy lowChoose fillers with a low solidification

    temperature

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    Aluminum Welding Procedures

    Select Joint Design & Fit up

    Bevel angles

    Square edge up to 3mm60 to 110 included angle

    Determine The Appropriate Inert

    Shielding Gas

    Argon or Argon/Helium

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    Select The Applicable Filler Metal

    60615086505250051100

    3003Base Metals

    4043

    4047

    5183

    5654

    5554

    5556

    5356

    5356

    5183

    5556

    5356

    5183

    5554

    5556

    5654

    4043

    4043

    5183

    5356

    5554

    5556

    5654

    4043

    40476061

    5356

    5183

    5556

    5356

    5183

    5556

    5356

    5183

    5556

    5356

    4043(A)5086

    5654

    5183

    5356

    5554

    55564043

    4043

    5183

    5356

    5556

    4047

    5183

    5356

    5556

    4043

    5052

    5183

    5356

    5556

    4043

    5183

    5356

    5556

    4043

    5005

    1100

    4043

    1100

    3003

    Sample

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    Set The Parameters

    Gas Flow

    (cfh)Gas CupAmps

    Filler Rod

    Size

    Tungsten

    SizeThickness

    203/8"70 - 1001/16" 3/32"1/16" 3/32"1/16"

    203/8"90 - 1201/8"3/32" 1/8"3/32"

    207/16"125 1751/8" 5/32"1/8" 5/32"1/8"

    257/16" 1/2"170 2255/32" 3/16"5/32" 3/16"3/16"

    301/2"220 2753/16"3/16" 1/4"1/4"

    355/8"330 3803/16" 1/4"1/4"3/8"

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    ALUMINUM WELDING TECHNIQUESAn initial arc is struck on a starting block to

    heat the electrode.The arc is held at the starting point until the

    metal liquefies and a weld pool is established.

    Add filler metal to the front or leading edge of

    the pool but to one side of the centerline.Both hands are moved in unison with a slight

    backward and forward motion along the joint.

    Arc length must be maintained to obtain

    sufficient penetration and avoid undercutting.

    Gradually lengthen the arc while adding fillermetal to the crater to prevent crater crack whenthe arc is broken.

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