Common Welding Issues in Aluminum Product

Aluminum welding often encounters specific problems due to its physical and chemical properties (e.g., high thermal conductivity, oxidation tendency, low melting point). Below are common welding machine issues and their causes:

1. Difficulty in Arc Starting

Causes:

The high electrical resistance of aluminum oxide (Al₂O₃) on the surface hinders arc ignition.

Unstable or insufficient welding current (e.g., failed high-frequency arc ignition in AC TIG welding).

Contaminated or improperly shaped tungsten electrode (in TIG welding).

Solutions:

Thoroughly clean the workpiece surface (mechanical grinding or chemical cleaning).

Check the high-frequency arc ignition system or adjust current settings.

Use pure tungsten or ceriated tungsten electrodes with a sharpened tip.

2. Porosity in Welds (Common Defect)

Causes:

Molten aluminum easily absorbs hydrogen (from oil, moisture, or impure shielding gas).

Insufficient shielding gas flow (e.g., argon purity < 99.99%) or contamination.

Contaminants on the filler wire or base metal (e.g., oil, oxide layer).

Solutions:

Preheat the workpiece (100-150°C) to reduce moisture.

Ensure proper shielding gas flow (typically 10-15 L/min).

Use dedicated aluminum filler wires (e.g., ER4043, ER5356) and keep them dry.

There are still many other problems but workshop need solve it very well so that can supply excellent welding aluminum products. Plesese kindly contact or talk with our engineer to share you idea.