Aluminum Welding

Techniques

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 Aluminium and its alloys
Abundant metal (8% of earth’s
crust).
Light weight.
Moderate to high strength
(depending on alloy).
High conductivity.
Corrosion resistant (Al2O3 coating).
Non-magnetic.
Good reflector.
 Wrought Alloy Designation
The wrought alloy designation system is
based 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
The first digit (Xxxx) indicates the
principal alloying element.

The second single digit (xXxx), if

different from 0, indicates a modification
of the specific alloy.

The third and fourth digits (xxXX) are

arbitrary numbers given to identify a
specific alloy in the series.
 CAST ALLOY DESIGNATION
The cast alloy designation system is based on a 3
digit-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.
 CAST ALLOY DESIGNATION
The first digit (Xxx.x) indicates the
principal alloying element.

The second and third digits (xXX.x)

are arbitrary numbers given to
identify a specific alloy in the series.

The number following the decimal

point indicates whether the alloy is a
casting (.0) or an ingot (.1 or .2).
 TEMPER DESIGNATION
The 1xxx, 3xxx, and 5xxx series are
strain hardenable only.
The 2xxx, 6xxx, and 7xxx series are
heat treatable.
The 4xxx series consist of both heat
treatable and non-heat treatable alloys.
The 2xx.x, 3xx.x, 4xx.x and 7xx.x
series are heat treatable.
TEMPER DESIGNATION

Basic Designations
F - As Fabricated
O - Annealed
H - Strain Hardened
W - Solution Heat Treated
T - Thermally Treated
 TEMPER DESIGNATION

As Fabricated
Applies to products of a
forming process in which no
special control over thermal
or strain hardening conditions
is employed.
 TEMPER DESIGNATION

Annealed
Applies to product which has
been heated to produce the
lowest strength condition to
improve ductility and
dimensional stability
 TEMPER DESIGNATION

Strain 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.
 TEMPER DESIGNATION

Solution Heat Treated

A process of heating the alloy
to an elevated temperature
(990°F) in order to put the
alloying elements or
compounds into solution.
 TEMPER DESIGNATION

Thermally Treated
Applies to product that has
been heat-treated,
sometimes with
supplementary strain-
hardening, to produce a
stable temper.
 TEMPER DESIGNATION
Aging
The precipitation of a
portion of the elements or
compounds from a
supersaturated solution in
order to yield desirable
properties.
SUBDIVISIONS OF H TEMPER
STRAIN HARDENED
The first digit after the H indicates a
basic operation:
H1 - Strain Hardened Only.
H2 - Strain Hardened and Partially
Annealed.
H3 - Strain Hardened and
Stabilized.
H4 - Strain Hardened and
Lacquered.
 SUBDIVISIONS OF H TEMPER
STRAIN HARDENED
The second digit after the H indicates
the degree of strain hardening:
HX2 – Quarter Hard
HX4 – Half Hard
HX6 – Three-Quarters Hard
HX8 – Full Hard
HX9 – Extra Hard
 SUBDIVISIONS OF T TEMPER
THERMALLY TREATED
T1 - Air Cool and Natural Aged.
T2 - Air Cool, Cold Worked and Natural
Aged.
T3 - Solution, Cool, Cold Worked and
Natural Aged.
T4 - Solution, Cool and Natural Aged.
T5 - Air Cool and Artificially Aged.
 SUBDIVISIONS OF T TEMPER
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, Cold Worked and Artificial
Aged.
 ALUMINUM ALLOYS AND
THEIR CHARACTERISTICS
1xxx Series Alloys (Non-heat treatable)
Pure Aluminium
99.0% minimum aluminum.
Excellent corrosion resistance.
Relatively poor mechanical properties.
Excellent electrical and thermal
conductivity.
Food, chemical, heat exchangers,
electrical wiring, capacitor foil.
Weldable.
 ALUMINUM ALLOYS AND
THEIR CHARACTERISTICS
2xxx 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 mechanical
components, vehicle body panels.
Weldability poor to fair depending on
alloy.
 ALUMINUM ALLOYS AND
THEIR CHARACTERISTICS
3xxx Series Alloys (Non-heat treatable)
Aluminum/manganese alloys
Manganese additions ranging from 0.05 to 1.8%
Excellent formability and
weldability.
Very high corrosion resistance.
Cans, chemical vessels, industrial
roofing, culvert pipe.
 ALUMINUM ALLOYS AND
THEIR CHARACTERISTICS
4xxx Series Alloys
(Heat treatable & non-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.
 ALUMINUM ALLOYS AND
THEIR CHARACTERISTICS
5xxx Series Alloys (Non-heat treatable)
Aluminum/magnesium alloys
Magnesium additions ranging from 0.2 to 6.2%
Moderate strength.
Good corrosion resistance.
Excellent weldability.
Shipbuilding, transportation,
pressure vessels, bridges and
buildings.
 ALUMINUM ALLOYS AND
THEIR CHARACTERISTICS
6xxx Series Alloys (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.
 ALUMINUM ALLOYS AND
THEIR CHARACTERISTICS
7xxx Series Alloys (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 weldability
depending on alloy and process.
Aircraft, aerospace, and competitive sporting
equipment.
 WELDING ALUMINUM ALLOYS
Aluminum Welding Difficulties
Aluminum 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 temperature
approaches the melting point.
Prone to contamination by O2, N2, H2.
Solidification cracking, particularly of many heat
treatable alloys.
WELDING ALUMINUM ALLOYS

Cleaning
Solvent cleaner, mechanical,
etching.
Weld pre-cleaning
Mechanical methods plus solvent
wipe
FILLER ALLOY SELECTION

Avoidance of cracking.
Tensile strength of weld.
Weld ductility.
Service temperature.
Corrosion resistance.
Colour match after anodising.
 Solidification cracking
Use matching filler for strain-hardened
grades
Don’t mix 4000 series and 5000 series
alloys (Mg2Si eutectics formed)
Don’t mix 5000 series and 2000 series
alloys
Many heat treatable grades are hot
short
No autogenous welding
Avoid high dilution
Medium copper grades are Unweldable
 HAZ cracking
Liquation cracking can occur in the
HAZ of age hardenable grades
Keep arc energy low
Choose fillers with a low solidification
temperature
 Aluminum Welding Procedures

Select Joint Design & Fit up

Bevel angles
Square edge up to 3mm
60˚ to 110˚ included angle
Determine The Appropriate Inert
Shielding Gas
Argon or Argon/Helium
Select The Applicable Filler Metal
Sample
1100
6061 5086 5052 5005 Base Metals
3003

4043
5356 4043
4047
5356 5183 5183
5183
5183 5554 5356 4043
5654 6061
5556 5556 5554 4047
5554
  5654 5556
5556
4043 5654
5356

5356 5356 5356

5356
  5183 5183 5183 5086
4043(A)
5556 5556 5556

5654
4043
5183 5183
5183
5356 5356
    5356 5052
5554 5556
5556
5556 4043
4047
4043

5183 5183
5356 5356
      5005
5556 5556
4043 4043

1100 1100
       
4043 3003
Set The Parameters
Gas Flow Filler Rod Tungsten
Gas Cup Amps Thickness
(cfh) Size Size

20 "3/8 100 - 70 "3/32 – "1/16 "3/32 – "1/16 "1/16

20 "3/8 120 - 90 "1/8 "1/8 – "3/32 "3/32

20 "7/16 175 – 125 "5/32 – "1/8 "5/32 – "1/8 "1/8

25 "1/2 – "7/16 225 – 170 "3/16 – "5/32 "3/16 – "5/32 "3/16

30 "1/2 275 – 220 "3/16 "1/4 – "3/16 "1/4

35 "5/8 380 – 330 "1/4 – "3/16 "1/4 "3/8

ALUMINUM WELDING TECHNIQUES
An 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 filler
metal to the crater to prevent crater crack when
the arc is broken.
THANKS