Custom Aluminum Welding
Aluminum welding is a sheet metal fabrication technique that combines heat and pressure to join two aluminum or aluminum-based alloy components. Aluminum can be welded using various methods such as TIG, MIG, plasma, laser beam welding and electron beam welding, and resistance welding.
KDM is a metal expert and specialized in offering outstanding aluminum welding services to clients worldwide. Aside from aluminum, we also weld a wide range of metals for a variety of applications such as stainless steel, carbon steel, galvanized steel, bronze, copper, alloy steel, brass, etc.
Using cutting-edge welding machinery, we assure to provide high-quality, high-precision, and clean finished products. Our process guarantees to reduce overall costs in the operation. Custom your products and services in KDM!
Benefits of Aluminum Welding
Aluminum welding eliminates the use of flux. Therefore, making the aluminum welded part free from corrosion.
Aluminum parts can be welded in any position. Therefore, it can offer high-speed welding and better visibility.
Aluminum is a lightweight metal therefore, it is very easy to weld while applying high-speed techniques and methods.
Aluminum welding offers a higher travel speed. Thus, enhancing the productivity, residual stress, and distortion possibilities.
Challenges for Aluminum Welding
Unlike welding iron or steel, welding aluminum should expect several challenges because of its unique characteristics.
Porosity. Hydrogen is soluble in liquid aluminum. During the welding process, filler material and the aluminum base metal become liquid. Thus, certainly absorbing the hydrogen. Once the welded metal solidifies, it cannot handle the hydrogen and will form into bubbles causing porosity.
Hot Cracking. Hydrogen cannot cause cracking to the welded aluminum. However, hot cracking may occur. To avoid this problem, choosing the right filler material is a big help.
How to Choose the Right Filler Metal
Choosing the right aluminum welding process types is not enough. Choosing an ideal filler metal also helps in achieving the best welding result. The best approach before choosing the right filler is to consider a chart for weld characteristics. Several factors should be considered before choosing a filler metal such as:
- Toughness and strength
- Crack sensitivity and post-weld heat treatment
- Corrosion resistance and ductility
- Elevated temperature service and color match
The Right Practices to Weld Aluminum Metal
The steps below are ideal practices to achieve the best aluminum welding result.
- Use a stringer bead instead of a weaving technique. The weaving technique is not suitable for aluminum. Using a stringer bead allows proper fusion and penetration. Higher heat inputs should be used for aluminum GMAW to ensure fast travel speed.
- The base metal should be cleaned thoroughly to remove moisture, residue, dirt, oil, and more to reduce the chances of porosity.
- Removing the aluminum oxide layer after cleaning.
Other practices that should be done include storing the base material properly, checking the consumables, and monitoring the temperatures.
KDM Aluminum Welding Service
KDM team is an expert manufacturer that specializes in offering different types of aluminum welding processes such as TIG and MIG for different aluminum thicknesses. Aluminum material is a porous metal. Therefore, removing oxide and preparing weld joints is critical. With KDM’s expertise and years of experience, we can handle even the most complicated aluminum welding process.
We offer inspection services, state-of-the-art welding equipment, and a proven welding process to ensure that we meet all the demanding requirements. We have aluminum welding service certifications such as ISO9001:2015. KDM provides excellent aluminum welding services for different industries such as aerospace, transportation, mining, heavy equipment, construction, and more.
Our factory is well-equipped with advanced welding machines such as shielded metal arc welding, flux-cored arc welding, and more. Below are the lists of our aluminum welding services advantages.
Excellent Heat Input Control
Our aluminum welding services can provide excellent heat input control, especially in MIG welding. Therefore, you can assure that the welded aluminum parts are not distorted or burned.
Bead Profile Management
The bead profile can be managed since the arc cone’s width can be modified using the control function. The right sizes can prevent over welding and removing excess heat input.
Due to our advanced technology, we offer fast and easy aluminum welding services. We have professional welders to ensure that we provide accurate welding processes.
Different Aluminum Welding Process
TIG aluminum welding is the most common welding method. This method is also called Tungsten Inert Gas welding. It won’t cause findability issues and other related problems since it doesn’t use mechanical wire feeding.
The filler material is fed into the puddle by using the hand. TIG aluminum welding is commonly used since it can produce a clean weld. It also helps in preventing the work area from being contaminated by the atmosphere.
This aluminum welding process integrates a wire that is continually fed that uses an electrode. To prevent the absorption of hydrogen, a gas mixture or inert gas is used to shield the wire. This method produces tiny metal beads.
The tiny metal beds are the result of the spray transfer method. Therefore, the process is somewhat messy. However, for experienced welders, this method is controllable and can produce a clean results. TIG aluminum welding process takes some time for a clean weld result.
Beam welding is an excellent process since it produces high power density for preventing a cold start. By using proper shielding, problems and issues relating to porosity and light reflectivity can be prevented. Here are the advantages of laser and electron beam welding:
- More manageable process
- Performed in a vacuum
- Doesn’t use light as an energy medium
Robotic aluminum welding uses an anthropomorphic robot. This is an automated aluminum welding in which the robot guides the torch to the welding point. For the best performance, frequency, voltage, current, wire feed, robot, and other welding parameters are necessary. The robotic aluminum welding process offers the following advantages:
- Precise final result
- Time optimization
- Resource optimization
Arc welding is the first welding technique that is discovered. Aluminum sheets are melted and jointed by using a power supply. Arch welding is more cost-effective than other aluminum welding processes. However, it should be done by an experienced welder.
On the other hand, resistance welding will require special tips and welding equipment. Because of the thermal conductivity of the aluminum metal, this process should take time to complete the weld successfully.
Aluminum Welding for Different Industries
We offer custom aluminum welding services for the automotive industry to offer corrosion resistance, fuel efficiency, and recyclability. Major automotive components produced through the aluminum welding process are drive shafts, engine cradles, rear or front suspension frames, radiators, heat exchangers, air conditioning units, and more. The suitable welding process for these component fabrications is MIG or GMAW.
Since the shipbuilding industry uses aluminum for efficient, low-maintenance, and fast transport, aluminum welding also advanced in the industry. This process is commonly used for the fabrication of different marine components. You can assure that aluminum welded parts for shipbuilding offers corrosion resistance, high strength, and are lightweight.
The aluminum welding process is a commonly used technique for fabricating sporting and recreation equipment for snowmobiles, sleds, golf clubs, bicycle frames, baseball bats, and more. Complex heat treatment and thin wall joining are possible through aluminum welding.
Transportation vehicles also benefit from the advancement of aluminum metal and processing. Therefore, aluminum welding is also common for aluminum parts fabrication. Truck panels and bodies are welded with 5356 filler alloy to ensure high strength.
For most aerospace and defense industries, aluminum alloys 7039 and 5083 are welded with filler alloys such as 5356. The welded aluminum parts are used for high-performance applications in the industry. Some parts are welded with their own characteristics for special considerations.
Aluminum Welding Precaution
Although aluminum has a unique characteristic, it can cause challenges in the welding process. Since aluminum is coated with alumina which is hard natural oxide, it can provide a higher density and melting point. Therefore, the following precautions should be considered.
- The alumina should not end up inside the molten aluminum bath. If this happens, cracks and brittle joints may occur.
- The alumina layer from the aluminum metal must be eliminated before welding. Another option is choosing the right filler accurately.
- To obtain more materials that can provide more corrosion resistance, aluminum is used in an alloy with another element.
Therefore, the alloy that will be used in the welding process should be according to the filler material and welding parameters.
Different Components Constructed Using Aluminum Welding
There is a wide range of aluminum components and parts that are fabricated using welding processes including:
- Aluminum engine components
- Aluminum irrigation pipes
- Aluminum shipping pallet
Welding Processes that are Not Suitable for Aluminum
Numerous processes that are not suitable for welding aluminum include the use of any flux such as:
- Submerged arc welding
- Flux-cored arc welding
- Stick welding
The mentioned welding processes are not effective for aluminum materials.
KDM Sheet Metal Fabrication Process – Aluminum Welding
KDM handles different sheet metal fabrication processes such as custom aluminum welding for different industrial projects. We can offer aluminum welding processes that conform to international standards for quality and safety. We specialize in MIG, TIG, Robotic, and other aluminum welding types. KDM has certified welding procedures handled by our expert welding team.