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Preparing for aluminum GTAW

Proper equipment setup and workplace preparation reduce defects
THE FABRICATOR APRIL 2001 (/publication/fab/issue/13 )
APRIL 24, 2001
BY: FRANK ARMAO (/AUTHOR/FRANK-ARMAO)

There are right ways and wrong ways to set up welding equipment to accommodate the aluminum
GTAW process. Welders should know how to troubleshoot this commonly used process and be
familiar with how to solve some common welding problems.

Todd Bridigum, welding instructor at Minneapolis

Community and Technical College and author of, How
to Weld, provides an overview of the various principles
behind welding aluminum successfully.

Even if you are experienced in welding steels, aluminum

welding can present quite a challenge. Aluminum's oxide
coating, higher thermal conductivity, and lower melting
point easily can lead to welding problems unless you
know how to prepare for welding and set up the
equipment.
Though many processes can be used to join aluminum,
the most applicable process for lighter gauges and
cosmetically appealing welds is gas tungsten arc welding
(GTAW). This article explores the correct ways to set up
welding equipment to accommodate the aluminum GTAW
process and also discusses techniques for
troubleshooting and solving common welding problems.

Advantages and Disadvantages of GTAW on

Aluminum

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There are advantages and disadvantages of using GTAW on aluminum. On the plus side, GTAW provides the highestquality welds and offers a great deal of versatility, meaning that you can weld many material thicknesses and joint
geometries. It also is easy to control and weld out of position. If an application has intricate welding requirements or uses
thinner materials, GTAW usually is the process of choice.
On the downside, GTAW is a relatively slow process with a low deposition rate. It generally is not used for high-volume
applications. In addition, the continuous high frequency associated with GTAW can interfere with robots, computers, and
other sensitive equipment.
GTAW often is used for such applications as aluminum bicycle frames, architectural components, piping, wheelchairs, and
aerospace work. It also is used to weld commercial airline engine casings, seat frames, and ductwork, as well as to repair
existing components, such as cylinder heads.

Polarity and Power Sources

Most materials welded by GTAW require direct current with the tungsten electrode negatively charged and the piece to be
welded positively charged. This is called straight polarity. In this mode, most of the arc's energy goes into the workpiece,
which results in the best weld penetration. Aluminum can be welded this way, but it is very difficult.
More often with GTAW, aluminum is welded using alternating current (AC). In AC welding, the arc's action when the
electrode is positive and the workpiece is negative, called reverse polarity, breaks up the oxide on the surface of the
aluminum, making welding much easier.Unfortunately, reverse polarity doesn't provide good weld penetration. While in
reverse polarity, much of the arc's energy goes into the tungsten electrode and the welding torch. For this reason, largerdiameter tungsten electrodes and heavier-duty torches, often water-cooled, are needed for AC welding.
The cleaning action created by the reverse polarity arc is important, but you do not want to clean more than is necessary,
so equipment manufacturers have created a balance control. Found on the front of the machine, the balance knob allows
you to adjust the amount of penetration (electrode negative) versus the amount of cleaning (electrode positive).

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As a rule of thumb, not as much cleaning is needed with high currents as with low currents. Some machines even offer an
autobalance feature that has preprogrammed balance based on the current being used.

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While changing to AC sounds easy, it creates an unstable arc. When you look at a sine wave, note that as the current
moves from positive to negative and then back again, it must pass through the zero point. When the voltage goes through
the zero point, the arc can go out or become unstable.

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To correct this unstable arc, welding manufacturers have

superimposed a low-current, high-voltage radio
frequency on top of the welding current. For most types
of welding, this high frequency is used only to initiate the
arc, but for aluminum GTAW, the high frequency is
present continuously and acts like a pilot arc.

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When selecting a power source, it usually is best to

select a newer-technology square wave model, which
alters the characteristics of the sine wave to create a
more stable arc (see Figure 1). In addition, look for a
balance feature, be it a manual or autobalance
adjustment.

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Workpiece Cleaning
Aluminum workpieces must be cleaner than steel
(http://image.thefabricator.com/a/preparing-for-aluminumworkpieces to be welded effectively. The first step is to
gtaw-square-wave-technology.gif)
remove oils and greases from the workpiece by wiping
Figure 1Object
the area with a solvent or washing it with a mild alkaline
solution. The second step is to remove all oxides, which can be done with a stainless steel wire brush. Never use the
same brush on aluminum and steel or it will become contaminated.
Not only do you need to clean before beginning to weld, but you also should remove the smut or soot between weld
passes. This soot is fine particles of aluminum oxide and magnesium oxide. Proper welding techniques will minimize the
amount of soot produced.

Shielding Gas
Usually, 100 percent argon gas is preferred for aluminum GTAW, but when working with thicker materials, such as 1/2 inch
or greater, add helium in the range of 25 to 50 percent. Helium makes the arc hotter and provides for more penetration.

Electrodes
Most operators who weld with DC polarity are accustomed to using a 2 percent thoriated electrode with a sharp tip. But for
AC aluminum welding, more heat is put into the tungsten, and the tungsten tip quickly becomes blunt. Once the tip is blunt,
using 2 percent thoriated electrodes results in a fluttering arc, which wanders around on the blunt tip.
Instead, start with a blunt tip and use a pure tungsten or zirconiated tungsten electrode. (A zirconiated electrode carries
more current than pure tungsten.) For AC welding, using a larger-diameter tungsten is advisable (see Figure 2) because
one that is too small spits tungsten into the weld, creating a defect. Consider using a ceriated or lanthanated electrode.
Both types of electrode are versatile and can be used for AC or DC welding.

Torches
If the welding application is light-duty fabrication requiring up to 150 amps, an air-cooled torch may suffice. Higheramperage jobs require a water-cooled torch used with a water recirculator. One feature to look for in a good torch is a
flexible head, which offers maneuverability and reaches tight areas. Because more heat input is used for AC aluminum
welding than for DC welding, a torch that normally is used for DC GTAW may not have sufficient capacity.

Filler Metal
As a rule, filler metal is added to welds made by GTAW. However, most nonheat-treatable aluminum alloys can be welded
without adding filler. This is referred to as an autogenous weld. Be careful, though, because if you try to weld any of the
heat-treatable alloys, such as 6061, without adding filler metal, they will crack during the welding process (see Figure 3).
As a caution, not all aluminum alloys are weldable. Be sure you know which type of aluminum alloy you are welding, and
then consult a filler metal chart. When handling filler metal, keep it dry in an airtight box to avoid contamination and a
buildup of hydrated oxide.
When welding is completed, the weld bead should be
bright and shiny without soot (see Figure 4).
Approximately 1/16 to 1/8 inch on each side of the weld
bead should have a bright strip, meaning that the oxide
has been removed from this area by the welding arc. If
the weld is black, an error has been made in the welding
process. In most cases, this results when the arc is too
long or the torch angle is wrong.
The weld also should have a distinct, uniform pattern of
ripples on the surface and should be smooth, blending in
well with the surrounding area. Remember that in steel,
the weld is as strong as the parent; in aluminum, this is
not always the case.

(http://image.thefabricator.com/a/preparing-for-aluminumgtaw-larger-diameter-tungsten.gif)
Figure 2Object

Conclusion

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Even if you are new to aluminum GTAW, you can reduce the number of errors you make by brushing up on how to set the
current and prepare the workpiece; selecting the proper gases, electrodes, and torches; and heeding advice from more
experienced welders. In time, you will feel as confident welding aluminum as you do welding steel.

Slide Show | 5 Images

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(http://image.thefabricator.com/a/preparing-for-aluminum-gtaw-aluminum-weldment.gif)

The Lincoln Electric Company

Frank Armao
Contributing Writer
The Lincoln Electric Company
22801 St. Clair Ave.
Cleveland, OH 44117
Phone: 216-481-8100
Fax: 216-486-1751

www.lincolnelectric.com
(http://www.lincolnelectric.com)
Contact via email
(mailto:frank_armao@lincolnelectric.com)

More Articles by Frank

Armao (/author/frank-armao)
He is a member of the AWS D1 Committee, chairman of the AWS D1 Aluminum Subcommittee, and vice chairman of
the AWS D8G Automotive Aluminum Arc Welding Committee.

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1 Comment

precision engineers

If you are required to weld thinner pieces of metal, your welding machine needs will be easily
accomplished by using a smaller less powerful machine.

Electric resistance welding at a glance

Metalworking throughout history

please provide me the infromatin

about the aluminum welding process ans its
avsilable of macihe

The potential of collaborative manufacturing Shop Strategies Tech Cell

Very good article, but would be

more correctly titled "Welding Throughout History",
since it doesn't discuss metal smithing,

How the welder shortage affects the

infrastructure - Welding Inspection Tech Cell

Hello, need to speak to someone

about a new metal Fab product?

Hello sir, my neighbor is a

structural welder, and I believe his experience was
with coal fired plants. He asked me to look into

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