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Welding on Aluminum Alloy Bodies - Welding Precautions
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The welding conditions for aluminum alloy must be set correctly and adjusted precisely during welding, because the allowable thickness range is rather limited when compared to welding steel panels. | |
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Compared to welding of steel panels, about 50% more shielding gas is required. | |
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When setting up the welding wire to the welding equipment, clean up the wire tip (edge) using sandpaper and push the wire through the torch by hand.
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Care should be taken to avoid damaging the inner liner of the welder’s cable. |
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Drive roller tension must be adjusted lower than when welding with steel wire. Hold the wire lightly at the contact tip and adjust the tension to allow slippage of the wire at the drive roller when the torch switch is turned on. If the drive roller tension is excessive, the wire can “bird’s nest”, or become jammed. Insufficient tension causes inconsistent wire speed. | |
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The wire feed speed is typically higher than when welding steel panels. | |
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The tip-to work clearance should basically be the same as when welding steel panels 8-15 mm (0.31-0.59 in). | |
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Use a push or forward welding technique with a torch of 5 to 15 degrees from the right angle against the work surface.
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Aluminum alloy tends to spatter during welding. Since it is very light, the weld spatter can be thrown over a considerable distance. Aluminum weld spatter is also difficult to see. | |
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It is important to provide protection for both the welder and also anyone in the surrounding areas. | |
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The edge of torch nozzle and contact tip attract spatter easily. If the spatter deposits, it disturbs the shield gas flow resulting in a poor welding quality. Be sure to remove the spatter thoroughly using anti- adhesion agent. | |
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The ware of torch nozzle and contact tip will be more excessive compared to the steel welding. | | | | | 
