Using Aluminum for your Welding Project

Aluminum is widely used in a range of industries, including construction and automotive production, where it is typically welded. As a corrosion-resistant material that is lightweight and durable, it is ideal for many applications.

However, its natural properties can make it more difficult to weld. For instance, aluminum has a melting point that is roughly half that of steel, and is a high thermal conductor, which makes it difficult for inexperienced welders to achieve a sound weld while also avoiding burning through the material and distorting it in the process. At the same time, the natural oxide layer on aluminum has a higher melting point than the metal itself. This means that aluminum’s corrosion-resistant layer actually makes it harder for the welding arc to penetrate the external oxide layer in order to initiate a weld, especially if aesthetic considerations are important to the job.

For those who are used to welding with steel, it will be necessary to learn new visual cues and to be more observant and intuitive when working with aluminum. Part of the difficulty lies in the fact that aluminum is often used as an alloy, or a mixture of various metals. This one fact makes it a unique case for welders. For the best success when welding with aluminum, it is often recommended to weld hot and fast. That requires experience, knowledge, and planning to ensure a good weld. The custom fabrication experts at M&M Certified Welding know a thing or two about welding with aluminum and would be happy to handle this part of your next project.

Types of Aluminum Welding

Much like other metals, there are several types of welding that can be done using aluminum. Each technique will always have its own quirks and key differences–an experienced welder will know how to handle the metal, whatever the type. When it comes to welding aluminum, there are several types of welding that can be reliably used.

GTAW/TIG

Gas tungsten arc welding (GTAW), or tungsten inert gas (TIG) welding, is just one of many types of welding that our mobile welding technicians perform for clients. This is a very popular process to use with aluminum, especially in the automotive field. AC capable equipment, argon gas, and a tungsten electrode are used. The resulting welds are clean and the aluminum is generally left uncontaminated from the welding process.

GMAW/MIG

Gas metal arc welding (GMAW) is more commonly called metal inert gas (MIG) welding, and is another area of expertise for our mobile welding team. MIG welding is commonly done with aluminum, though due to the faster nature of the process it can result in less ideal welds when compared to GTAW/TIG welds. Cleanliness, dry conditions, and ample coverage from shielding gas are vital for the best outcome.

SMAW/FCAW

Other common forms of welding when using aluminum include laser beam and electron beam welding, resistance welding, and shielded metal arc welding (SMAW). On the other hand, flux-cored arc welding (FCAW), submerged arc welding and stick welding are generally not recommended for use with aluminum, since flux has been known to cause porosity, a situation in which gas becomes trapped in the weld pool. This produces a weak and less than ideal weld.

No matter the type of welding you’re pursuing when using aluminum, the most important thing to do is to avoid defaulting to the knowledge you’ve acquired while welding steel. These are very different materials that often require different welding methods for the best outcome. As with any well-honed craft, there cannot be a one-size-fits-all approach here, and taking safety seriously is a must. But with the right materials, equipment, techniques and mindset, aluminum welding is most definitely possible, and in fact, preferred in some cases.

Expert Welding Services In Cleveland

There may be an array of welding companies in Cleveland to choose from when you need professional welding done for a project, but why not work with the best? At M&M Certified Welding, our expert welders can tackle any of your welding needs, from truck body fabrication and custom fabrication to other mobile welding services needs. Residential, commercial, industrial–they handle it all. From product design to completion or repair, feel free to walk in, request an online quote, or contact us to learn more about all of the welding services we offer.