Aluminum Welding for Beginners

Equipment

• MIG welding uses a welding gun. The welding gun feeds an electrified wire to the area being joined. Electrifying the wire causes it to melt into the joint. A protective gas that prevents the electrical current from jumping up and hitting the welder is shot out of the gun at the same time. The copper-coated wire is sometimes chemically treated to prevent the melting wire from splattering.

Safety Equipment

• The electrical current causes large, hot, bright sparks to occur. Heavy welding gloves are used to prevent the hands from being burnt by splatter or electricity. A special MIG welding mask with a darkened visor prevents the bright spark made from the electrical current from blinding the user. A clean work area, free of flammable materials, is essential. Long-sleeved, nonflammable work clothes are also a must.

Cleaning

• The most important step of a good aluminum weld is cleaning the aluminum before beginning. Dirty aluminum will cause the electricity from the MIG gun to arc, the filler wire to stray from the aluminum surface and larger gaps to appear between the aluminum pieces. Aluminum should be sprayed with acetone, then rinsed with clean water. Scrubbing the aluminum with a stainless steel brush removes any residue and scores the aluminum surface for a better weld.

Welding Tips

• Work materials should be clamped to a heat sink made of copper to prevent heat transfer. This prevents shrinking and warping of the aluminum. The aluminum should be preheated to a temperature between 275 and 500 degrees Fahrenheit. The two aluminum parts are fitted as closely together as possible to keep the gap being filled by the weld as small as possible. Welders set the amperage of the welding gun to one amp per every .001 inch of material.