Welding aluminum is unlike welding other materials, such as iron. You will need to take more time to prepare the materials if you want a clean, strong weld, and your welding technique will need to be modified as well. In some applications, you may need to pre-heat the metal prior to welding. Although it takes more prep time and a different welding style, with a little practice, you can achieve a clean and solid weld on a piece of aluminum.
Safety First
When welding any type of material, wear all needed safety gear. This includes gloves, hearing protection and a heavy apron to protect your body from hot splatter. Wear eye protection to shield your eyes from thermal burns. Make certain the work area is well ventilated in order to remove the fumes generated when welding. As an added precaution, keep your face away from the fumes as much as possible.
Material Preparation
Prepare the aluminum. The first step in this process is to clean away any lubricants. Next, remove the aluminum oxide from the surface of the metal with a metal brush. Brush in only one direction, and do not use a brush that has been used on other materials. It is necessary to remove the aluminum oxide due to the vast differences in melting points for the aluminum oxide and the base aluminum. While pre-heating is not generally necessary, if you are welding two pieces of different gauge aluminum, preheating can help prevent some problems. If you pre-heat the aluminum, do not exceed 230 degrees F.
Welding Technique
Aluminum has a much higher thermal conductivity than other materials; higher amperage and voltage is required to achieve a solid weld. Weld at a fast pace to keep the weld smooth and even. With materials such as iron, it is normal to pull the weld toward you. When welding aluminum, always push the weld away from you. Attempt to keep the welding tip at a 10-to-15 degree angle for best results. The keys are to weld hot, weld fast and push the weld away from you. This will result in a solid weld that's clean and strong.
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