Beruflich Dokumente
Kultur Dokumente
By Chris Roehl
March 7, 2006
While using aluminum can present challenges in any welding application, knowing the right questions to ask beforehand will help aid success. Issues include knowing what aluminum filler metal to use, how to store it, and what options are available to help eliminate feeding problems.
Aluminum, especially thin-gauge, presents unique welding obstacles. Gas metal arc welding (GMAW) in particular presents challenges in wire feeding and selecting the right type of filler metal and equipment. However, several options can aid in effective aluminum welding. In its pure form, aluminum is a relatively soft metal that has many uses but requires adding one or more alloys to increase its strength and add qualities that make it suitable for different applications. Common alloys are copper, magnesium, silicon, manganese, and zinc. They are identified by their series numbers:
Alloy Group 99 percent minimum aluminum purity Copper Manganese Silicon Magnesium Magnesium-silicon Zinc Other
The following are five questions welders frequently ask when deciding how best to weld aluminum.
Joint design Dilution (when the filler wire and base metal combine in the weld puddle to create a different chemical makeup in the weld) Weld strength Cracking tendencies Ductility Corrosion in service Color matching if the material is anodized
Different filler metals address these considerations to varying degrees. In general, if strength is the primary concern, the filler metal should match the base metal closely in tensile, yield, and ductility. Most consumables manufacturers, as well as the American Welding Society (AWS), offer information listing the relative values of these qualities of their filler metals for each base alloy.
4. I've heard that feeding aluminum can be difficult. What feeding options are available for aluminum wire?
Because aluminum wire has low columnar strength, feeding it has been likened to pushing a wet noodle through a straw. Birdnesting, or the tangling of the wire between the drive roll and the liner, is a common, time-consuming, and costly problem. Clearing it requires the operator to stop welding, cut the wire, discard the wire in the gun, and re-feed new wire through the liner. It also may require cleaning or changing the contact tip because of the burnback caused when the wire stops feeding.
Several types of systems can feed aluminum wire: Push Only. Feeding aluminum wire through a push-only system can be difficult, but it can be done on a limited basis. It requires U-groove drive rolls to provide more surface contact with the wire, a Teflon liner, adequate drive-roll pressure, the ability to keep the gun cable straight, and a high tolerance for pain. Any resistance in the line likely will cause the wire to misfeed. Thicker wire, such as 1/16 inch, can be fed consistently in a push-feed system. However, push feeding isn't very dependable for thinner gauges, such as 0.030-in. wire. Spool Gun. A spool gun helps eliminate birdnesting by putting a 4-in. (1-pound) spool on the gun so the wire feeds only a few inches. Spool guns can accommodate aluminum wire diameters from 0.023 to 1/16 in. and allow the operator to use longer cables, generally from 15 feet to 50 ft. The roll in a spool gun needs to be changed after every pound of wire is used. In tight spaces, the spool may limit access, requiring the operator to use a longer stick-out. If the operator uses several pounds of aluminum per day, the few minutes needed to change spools can add up. Also, burnback is a possibility when the end of a spool is reached, so many operators stop even though a few turns are left on the spool. Push-Pull Gun. On a push-pull gun, a motor in the gun pulls the wire through the liner, while the motor in the welding machine or feeder control becomes an assist motor. By maintaining consistent tension on the wire, the push-pull system helps eliminate birdnesting. Because the weight of the spool isn't in the operator's hands, a push-pull gun can offer ergonomic benefits. With a push-pull gun, the spool needs to be changed less often than with a spool gun, and larger spools can be used. Cables up to 50 ft. long can be used with a push-pull gun. A push-pull system can be more expensive than other types of systems, but it can offer increased productivity and the ability to buy larger spools. Continuous-feed Push System. This system is relatively new. Its drive system maintains continuous contact with the wire and helps eliminate birdnesting by removing the gap between the drive rolls and the liner. It's limited to pushing wire 15 ft., but the gun is lighter than a spool gun or a push-pull gun and requires no additional maintenance.