Aluminium Sheet Welding

Thick can present numerous problems such as bum through and tough starts.

Aluminium sheet welding.

Welding aluminum is not as hard as you think. Aluminum is quite reactive so forms an oxide layer when it s exposed. If travel speed is too slow the welder risks excessive burnthrough particularly on thin gage aluminum sheet. Using too small a filler rod can be a problem too.

Welding aluminium is just different from welding steel. Aluminum is a lightweight thin metal which is used very commonly in welding workshops. But first a word about safety before you start welding make sure the area is well ventilated. However aluminum sheet less than 1 8 in.

Another rule of thumb for tig welding sheet metal thicknesses is try not to use a filler rod that is thicker than the metal you are welding. I used 1 16 1 6m 4043 rod for this outside corner joint in 040 and it worked out ok. With this metal welding has to be done at low temperatures or else you will just end up blowing holes in your materials. The more time the arc is in an area the hotter it.

It may take some practice so here are some tips for welding aluminium. To prevent burn through and warping don t whip or weave the torch. Techniques for welding sheet metal. Typical aluminum alloys for sheet fabrication are 3003 and 5052.

Unless alloyed with specific elements it is suitable only in low temperature applications. A 5356 filler metal also works for 5052 materials specifically. It makes for a very strong bond and with a little practice can be done quickly with great looking results. However if you are dealing with materials that are 18 gauge or thicker one should be able to use 030 inch welding wire.

Filler metals for either of these would be 4043 or 4943. Aluminum is a lightweight soft low strength metal that can easily be cast forged machined formed and welded. As a rule when mig welding sheet metal never use a body filler metal that is thicker than the base metal. High weld speed and low distortion properties on steel sheet have ensured its home in these shops when used properly.

Turns out you can weld aluminum without a welder. Aluminum welding needs to be performed hot and fast unlike steel the high thermal conductivity of aluminum dictates use of hotter amperage and voltage settings and higher weld travel speeds. It is recommended that a welder should use 023 or 024 inch wire for light gauge sheet metal work. Mig gmaw welding the most popular welding machine in the collision repair shop by far is the mig welder.