[Chinese aluminum industry network] Aspect 01 aluminum welding 5 tips 1. It is a wire-type welding torch that is more suitable for welding aluminum materials. If you can't use this kind of welding torch, try to use a shorter welding torch in order to keep the welding torch straight; use only argon as a shielding gas; in the welding of aluminum (automatic tube Only use pusher tactics when welding. 2. If you find a wire feed problem, try a conductive head that is one size larger than the wire. 3. The more commonly used welding wire for welding aluminum is a softer standard welding wire. The other is harder (easier to feed the wire) and it is mainly used in welding operations where hardness and strength are required. 4. Before the start of welding, remove the oxide layer on the surface of the aluminum. Use a special stainless steel brush to remove the oxide layer. 5. Fill arc pits at the end of welding to prevent cracks. One option is to hold the torch in the bath for a few seconds after welding. Aspect 02 Aluminum Welding Precautions 1. Welding of aluminum Welding characteristics: Aluminum and aluminum alloys have features such as high thermal conductivity, large heat capacity, large linear expansion coefficient, low melting point, and low high temperature strength. It is difficult to weld and certain measures should be taken to ensure welding quality. The cleaning of pipe fittings and welding wire, the surface of the wire within 50mm of both sides of the wire and breakage is cleaned with acetone, the surface oxide film is brushed with a stainless steel wire brush to expose the metal luster, and the clean break must be welded within 2 hours. The wire is placed in an unused cartridge and must be used within 8 hours or it will be reprocessed. Tungsten rods are made of tantalum-tungsten rods. Argon bluntness is not less than 99.96%, and the water content should not exceed 50 mg/m3. The ambient temperature should not be lower than 5°C, otherwise it should be preheated to 100°C to 200°C before welding. Relative humidity control. 2. Equipment needed You need to have at least a $4,000 welder and superb welding skills to weld the aluminum; you do not need to practice to do a good job of welding; you need to buy an expensive torch that is suitable for aluminum welding. 3. Successfully welding aluminum The fact is that a compact, compact MIG welder can also perform temporary aluminum welding operations after training, using suitable welding equipment, and setting the correct parameters. You will be able to use the MIG welder to complete all kinds of material welding in your home, such as barbecue grills, backyard storage rooms, docks, and even decorative parts. Even home welding enthusiasts who often weld steel will find it a challenge to weld aluminum. The reason is: Aluminum wire is very soft, and wire feeding is quite difficult. In addition, wire diameters and welder settings typically used for steel may not be suitable for welding aluminum. Aspect 03 To successfully weld aluminum, understand the following issues 1. What kind of equipment do I need? The first decision that needs to be made is what kind of equipment is needed to achieve the goal. Keep in mind that a 115-volt wire feeder can handle 22- to 12-gauge welding jobs, and with proper warm-up, you may be able to weld 1/8-inch thick materials. But be careful, the larger value of preheating is limited to 250 degrees Fahrenheit. The other is a 230-volt machine that can weld material from size 22 up to 3/16 inch. Proper warm-up can increase the range to 1/4 inch. If you need to weld a variety of different thicknesses, consider a 230-volt welder. Remember, if you are planning to do very regular aluminum machining, you will need a heavy welder. The 115- and 230-volt compact MIG welders can perform occasional aluminum welding, but it is not recommended to use them for complex, heavy aluminum welding, or else welding equipment that outputs more than 200 amps should be considered. After you have determined the input voltage, the other question you usually ask when choosing a welder is, do I need a continuous voltage regulation model or a tap-type model? The continuous voltage regulation model allows you to steplessly adjust the set voltage within the voltage limits of the machine. The adaptability is stronger, and more accurate adjustment and accurate control are possible. This allows you to make adjustments easier during welding operations. 2. What kind of protective gas? The protective gas required for MIG welding of aluminum and welded steel is different. For welding aluminum, 100% argon should be selected. However, steel welding requires mixed gas or 100% carbon dioxide gas. The good news is that we don't need any special equipment - your existing regulators (other than CO2 regulators) and tracheals can be used in pure or mixed gas. 3. What kind of polarity is set? All MIG welding, including aluminum welding, requires a positive electrode, whereas the flux core welding process typically uses a negative electrode. If you want to switch the welder in different processes, first determine the switching polarity. This is a mistake that novices often make. 4. What kind of aluminum alloy electrode should be purchased? If you try to use a steel electrode when welding aluminum, you will get poor results. Instead, we recommend that compact MIG welders use a 4043-inch diameter 4043 aluminum alloy filler metal. The 5336 aluminum alloy electrode may be generally recommended to retailers and distributors because the wire is harder and easier to feed. However, with this type of wire feeder, the 5356 aluminum alloy usually has insufficient current to achieve good welding results. Although the 4030 is soft, good wire feeding performance can be ensured by following the appropriate steps described below. Do not use other diameter wire. In particular, 0.030-inch wires (difficult to feed wire) and 3/64-inch wires (a small, compact welder that does not provide enough current to reliably melt this wire diameter) are avoided. 5. How can I set up my welder to weld aluminum? Since you know the type and performance/limitation of the welding machine needed, the next important step is how to set the parameters. Follow these tips: Buy an aluminum wire feeding tool; pay attention to wire feeding when welding aluminum. It is even more important, so it is strongly recommended to purchase a dedicated aluminum wire feeder. A set of tools will contain the following items: Non-metallic liners - designed to reduce delivery Wire friction 2. U-slot drive rollers - used to avoid breaking or deforming the soft aluminum wire, these drive rollers do not scratch the aluminum wire like V-groove rollers. The use of a V-groove roller causes plugging of the wire-scraping liner, causing wire feed failures. Inlet and outlet guides - designed to avoid welding wire scratches Contact heads - use of larger diameter openings in contact heads welded on aluminum, because when aluminum heats up, more expansion occurs than steel. Therefore, the size of the special contact for aluminum wire is small enough to keep the electrical contact, but it is also sufficient to allow expansion. Loading wire to welder Here is a trick to properly insert aluminum wire, (also suitable for steel wire) is very important for loading aluminum wire to avoid welding failures. Hold the wire shaft securely with one hand to make sure it does not loosen. Once you have unpacked the cellophane, hold the loose wire with your other hand - do not put it in the drive roller let go. Inexperienced people usually do not grasp the loose one and cause the entire bundle of wires to begin to loosen. If this happens, it will not be remedied. Welding operations will also be greatly affected - you have to buy another bundle of welding wire. Set the tightness of the wire brake The tightness only needs to ensure that the welding wire is not loosened, but it should not be too tight, otherwise it will cause the welding wire to drag. To set up properly, first adjust the tightness to a low level, then attach the welding wire and let it pass the driving roller. If the roller except the welding wire is moving and the other parts are stopped, it means that the welding is not tight enough. Be careful when handling, because too much force will cause too much force on the wire. In addition, don't be nervous when the wire isn't feeding the next few laps; it's usually because the wire is too hard to loosen. Set the tension of the drive roller This may be a more important step in the entire setup process. Experts recommend placing the tip 1 inch from the surface of the insulating material at a slight angle. Then, set the roller tension to be almost small. Press the switch on the torch and observe its operation - it should slide when the wire touches the surface of the insulating material. From that point, tighten the tightness until the wire stops sliding. Again, note that too tight can lead to wire breakage. This means that the welding wire stays in the welding torch and the wire drive roller is still rotating. As a result, the wire will break after running out of the roller, or the backlog will cause the wire to clutter, including the guide liner and the gun liner. Keep in mind that when you set the tightness of the roller as described above, press the torch switch and the wire is hot, so always wear good quality welding gloves. Ensure good power connection By the way forward, the welding fixture should be securely clamped in the area where the welding workpiece is not painted and contaminated. To clean the workpiece, use grease removal solvent to remove all grease. Before welding, ensure that the workpiece surface is dry. At the same time, do not weld with flammable materials in the vicinity, such as solvents or paint containers. The second step is to clean the surface oxides of the aluminum material with a clean stainless steel wire brush. Positioning is very important When welding, try to keep the torch cable straight, to reduce the wire feed restriction on the softer aluminum wire to a greater extent. The bending of the torch cable can cause the wire to knot, resulting in poor wire feeding. 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