Guide to Welding Aluminum

By Brayan Peter

Professional welding actually involves expertise & experience. A fairly extensive-knowledge is required to become an expert. Many years of exposure & skill are necessary to master the art of welding. After understanding the basics, one can learn more complicated skills.

First and foremost, one has to take safety precautions. Otherwise, unforeseen circumstances may even prove to be fatal. Damage to the eyes is a possibility due to intense light beams that emerge from the course of action. As electricity is involved in certain cases of welding, death by electrocution is a possibility. Before starting welding, helmet has to be worn for protecting eyes, hair, head & face. Wearing protective gloves & clothing is a must.

Arc Welding:

Arc welding is the most common technique used. It is the first lesson for welding. Instead of using a gas torch, high voltage electricity is to be used. In arc welding, a spark/arc is able to melt a metal & form a weld. This process is accepted by many as it is more accurate & produces a cleaner & stronger weld. In the category of arc welding, seven different methods are there to choose from.

Shielded metal arc welding may be the most suitable if you have large welds or metal welding in not-so-normal angles & positions. In this method, the electricity passes through an electrode using which metals can be melted. MIG welding (Metal Inert Gas welding) will be useful in a welding project which requires more speed. In this method, rods need not be used. In its place, equipment has to be used that passes current through a metal tip that does not melt. A separate piece of continuous wire is to be fed to the tip which forms the weld. Tungsten inert gas welding is slightly similar to MIG welding. It is applicable in thin materials where high quality weld is required & where speed is not necessary. There are other methods also – namely Flux-Cored arc welding (FCAW), submerged arc welding (SAW), plasma welding etc.

Aluminum Welding:

Aluminum is the most difficult alloy. Initially, aluminum oxide should be cleaned from the surface. Heat treatable aluminum alloys receive their strength from a process called ageing. Notable decrease in tensile strength will happen when welding aluminum due to over-ageing. For all other information on aluminum welding processes, please visit the homepage or any of the links connected to this.

Aluminum alloys can be divided into 9 groups.

Designation Major Alloying Element

1xxx unalloyed (pure) >99% Al

2xxx Copper is the principle alloying element.

3xxx Manganese is the principle alloying element.

4xxx Silicon is the principle alloying element.

5xxx Magnesium is the principle alloying element.

6xxx Magnesium & Silicon are principle alloying elements.

7xxx Zinc is the principle alloying element.

8xxx other elements (including Tin, some Lithium compositions)

9xxx reserved for future use

Aluminum alloys are readily available in the market. We can get them in various product forms. The following are the factors affecting aluminum welding.

* Aluminum Oxide coating.

* Thermal Conductivity.

* Thermal Expansion Coefficient.

* Melting characteristics.

Other welding Methods:

There are some other methods – resistance welding, energy beam welding & solid state welding. All these methods are useful in industrial applications where large scale & specialized requirements are involved.

What we have dealt with so far are only basic concepts. These are the fist lessons or fundamental steps from which on can go further to acquire more knowledge about welding procedures. One has to remember only a couple of basic methods. One has to practice a lot before arriving at a standard of excellence. Certain processes will bring easy results & some may not. Sooner or later, one will reach a stage & style which will be most comfortable for future operations.

Peter is a seo copywriter for Welding Supply, Welding Equipments. He written many articles like Welders, Welding Machines, TIG Welding Equipment, welding helmets. For more information visit our site Contact him through mail at

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