Technical update

Maintenance Welding of Aluminum

By Leif Andersen, TE Andersen Consulting.

Hardly any other metal gives as many difficulties as maintenance welding of Aluminum. Most
welders avoid getting involved trying to repair or manufacture items made of aluminum because
it simply requires a complete different welding / handling procedure compared to other more
common metals like steel or stainless steel. This paper outlines information on the different
alloys and realistic welding methods and procedures for performing maintenance welding
onboard.

Introduction
Aluminum is the most widely used metal in engineering apart from iron. The reason why aluminum
is widely used is because the combination of properties makes it one of the most versatile of
engineering and construction materials. Aluminum is light in weight, yet some of its alloys have
strengths greater than that of structural steel. It has good electrical and thermal conductivities and high
reflectivity to both heat and light. It is highly corrosion resistant under a great many service conditions
and is nontoxic. Aluminum can be cast, extruded, forged, drawn, hot rolled and cold rolled.

Aluminum and its alloys

Aluminum is available as Wrought (shaping processes: rolling, forging, extrusion, pressing, stamping)
and Cast Aluminum alloys. Alloy systems are classified by a number system American National
Standards Institute (ANSI) or by names indicating their main alloying constituents (DIN and ISO).
The main alloying elements are copper, zinc, magnesium, silicon, manganese and lithium. Small
additions of chromium, titanium, zirconium, lead, bismuth and nickel are also made and iron is
invariably present in small quantities. Wrought alloys are normally identified by a four-digit system (for
example ANSI 1XXX) which identifies the alloying elements. The system which originated in the USA
is now universally accepted. Cast alloys have similar designations and use a four to five-digit number
with a decimal point (for example ANSI 4XXX0). The digit in the hundreds place indicates the alloying
elements, while the digit after the decimal point indicates the form (cast shape or ingot).
Most aluminum alloys are weldable using Gas Welding/ Brazing, Electrode/Stick, TIG or MIG welding.
However, some are not. Let us take a quick look at the common families of aluminum alloys, their
weldability characteristics and what filler material to use:

1XXX alloys. Essentially pure aluminum (99 % pure) and used to carry electrical current or for
corrosion resistance in specific environments, these alloys are all weldable. The most
common filler metal is 1100. AWS/SFA 5.10 ER1100. For example, Washington Alloy 1100
(commonly referred to as Al99.5) is a 99% aluminum filler metal that is available in spools or
cut lengths for MIG or TIG welding processes.

3XXX alloys. Alloying element Manganese. Comes as wrought only. This family comprises
medium-strength alloys that are very formable. They are often used for heat exchangers and
air conditioners. All are weldable using either 4043 (ANSI/AWS A5.10 (ER & R), AMS 4190.
EN ISO 18273 designation AlSi. Similar to AlSi5, BS N21) or 5356 (ANSI/AWS A5.10 (ER &
R). EN ISO designation AlMg5Cr(A). Similar to AlMg5 (DIN)) filler metal.

4XXX alloys. Alloying element Silicon. These are used as welding or brazing filler alloys.
However, they are sometimes used as base materials. If that is the case, they are readily
 welded with 4043 (ANSI/AWS A5.10 (ER & R), AMS 4190. EN ISO 18273 designation AlSi.
Similar to AlSi5, BS N21) filler metal.

5XXX alloys. Alloying element Magnesium (seawater resistant aluminum). This is a family of
high-strength sheet and plate alloys. All of them are welded using 5356 (ANSI/AWS A5.10
(ER & R). EN ISO designation AlMg5Cr(A). Similar to AlMg5 (DIN)) filler metal, although 5183
(ANSI/AWS A5.10(ER & R. EN ISO designation AlMg4.5Mn0.7(A) Similar to AlMg4.5M) or
5556 (ANSI/AWS A5.10 (ER & R). EN ISO designation AlMg5Cr(A). Similar to AlMg5 (DIN))
should be used for the stronger alloys, such as 5083.

6XXX alloys. Alloying elements Magnesium and Silicon. These are primarily the extrusion
alloys, although they are available in sheet and plate as well. They are prone to be crack-
sensitive. However, with the proper techniques, they can all be welded using 4043
(ANSI/AWS A5.10 (ER & R), AMS 4190. EN ISO 18273 designation AlSi. Similar to AlSi5, BS
N21) or 5356 ((ANSI/AWS A5.10 (ER & R). EN ISO designation AlMg5Cr(A). Similar to AlMg5
(DIN)) filler metal.

So, what about the 2XXX and 7XXX alloys?

2XXX alloys. Alloying element Copper. These are high-strength aerospace alloys in sheet or
plate form. Their chemistry makes most of them un-weldable using TIG or MIG because of hot
cracking. The exceptions are 2219 and 2519, which are both welded using 2319 (ANSI/AWS
A5.10(ER & R), AMS 4191) or 4043 (ANSI/AWS A5.10 (ER & R), AMS 4190. EN ISO 18273
designation AlSi. Similar to AlSi5, BS N21) filler metal. In any case, you should never weld
2024. It is very common and very high in strength, but it is extremely crack-sensitive.

7XXX alloys. Alloying element Zinc. This too is a family of high-strength aerospace alloys.
Like the 2XXX alloys, most of them are un-weldable using TIG or MIG because of hot-cracking
and stress-corrosion concerns. The exceptions are 7003 and 7005 extrusion alloys and 7039
plate alloys. All three of are readily weldable using 5356 (ANSI/AWS A5.10 (ER & R). EN ISO
designation AlMg5Cr(A). Similar to AlMg5 (DIN)) fillers. Never weld 7075.

Alloys of 1xxx, 3xxx, 4xxx and 5xxx series are non-heat-treatable. The initial strength of these alloys is
achieved due to the hardening effect of the alloying elements: manganese (Mn), silicon (Si),
magnesium (Mg).

Heat-treatable alloys can be strengthened by heat treatment. Alloys of 2xxx, 6xxx and 7xxx series are
heat-treatable. The initial strength of these alloys is achieved due to the hardening effect of the
alloying elements: copper (Cu), silicon (Si), magnesium (Mg) and zinc(Zn).

NB. Welding heat-treatable alloys can to a higher or lesser degree influence on the items mechanical
properties.

Two fillers stand out. When should I use 4043 or 5356 as filler?

As a basic description we can say that 4043 is an aluminum filler alloy with 5% silicon added and
that 5356 is an aluminum filler alloy with 5% magnesium added.

When should we choose one of these filler alloys over the other?

When the filler alloy selection allows the use of either 4043 or 5356 as filler for a specific base
alloy, as a guide, we may wish to consider the following facts about each of these filler alloys.
4043 should not be used if you are considering the best color match after post weld anodizing,
as this filler alloy will typically turn dark gray in color after the anodizing process. 5356 will
provide a much closer color match after anodizing.
4043 is suitable for service temperatures above 65OC (150OF), however, 5356, because of its
5% magnesium content is not suitable for these elevated temperature applications.
 4043 has lower ductility than that of 5356. This may be of some consideration if forming, after
welding is to be carried out.
4043 has lower shear strength than that of 5356. This may be of consideration when calculating
the size of fillet welds.
4043 is a softer alloy in the form of spooled wire, when compared to 5356. Typically, when MIG
Welding (GMAW), feed ability will become a less critical issue when feeding the more rigid 5356
alloys.
4043 will typically provide a higher rating for weldability and provide slightly lower crack
sensitivity. 4043 will generally tend to produce welds with improved cosmetic appearance,
smoother surfaces, less spatter and less smut. For this reason, it is sometimes more appealing
to the welder.

Anodized aluminum
Anodized aluminum is simply standard aluminum that has been treated to produce a thick layer of
oxides on its surface. The process of anodizing uses an electrolytic chemical application, usually with
sulfuric acid, to create a layer of oxides several times thicker than would naturally form — 0,0051mm
(0.0002 inch) to 0,0254mm (0.001 inch) thick. The aluminum base is a very soft material and melts at
approximately 660 OC (1220 OF), but the oxide layer is extremely hard (some types approach the
hardness of diamonds) and melts at 2000 OC (3,600 OF). The difficulty in welding anodized aluminum
lies in removing the oxide layer without burning through the aluminum base. The four types of
anodized aluminum are standard, bright-finish, colored, and hardened. Bright-finish anodized
aluminum can be visually distinguished from standard anodized aluminum by its shiny, chrome like
finish. This type of material has a thicker layer of oxides than standard anodized aluminum, making it
more difficult to TIG weld, and is used primarily for cosmetic reasons. Colored anodized aluminum is
also used for cosmetic purposes. This material uses dyes in the anodization process, which allow the
material to take on different hues, but also introduce potential contaminants into the weld. Hardened
anodized aluminum is almost as hard as a diamond and is very difficult to weld. This type of material is
usually used only in highly specialized industrial applications. Welding procedure: look under TIG
welding.

How to identify aluminum?

Magnetic Test: Non-Magnetic
Spark Test: No Spark (use angle grinder)
Color: White
Relative weight: Light (compared to other components of same size and shape)

The difficulty can be to identify Aluminum and Aluminum alloys from Magnesium and Magnesium
alloys. A simple test to find out is to file some shavings of the component onto a paper. Hold the
paper over an oxy- acetylene flame and let the shavings fall into the flame. If the shavings glow
the metal is aluminum. If some of the shavings spark in the flame the aluminum is alloyed with
magnesium (seawater resistant aluminum). If all the shaving spark in the flame, the metal is
magnesium and must not be welded.
What makes it so difficult to weld aluminum?
The oxide coating on aluminum alloys causes difficulty in relation to its weld ability. It also has high
thermal conductivity and a very short temperature range between liquidus and solidus and when
liquid its viscosity is very low. During fusion welding, the aluminum would oxidize so readily that
special fluxes or protective inert‐gas atmospheres must be employed.

Aluminum oxide

Aluminum

Aluminum quickly forms a more or less invisible coating of aluminum oxide. Aluminum oxide melts at
three times the temperature of aluminum. When you try to weld uncleaned aluminum, the aluminum
under the aluminum oxide coating will melt but the aluminum oxide coating will stay solid and act as a
membrane, much like a water balloon. When you finally succeed in penetrating the coating, the very
runny aluminum inside will flow out all at once, much like a bursting water balloon. The oxide is also
heavier than aluminum and, when melted, tends to sink or be trapped in the molten aluminum. For
these reasons, it is easy to see why as much as possible of this oxide "skin" must be removed before
welding.

Aluminum oxide
Melting point 2038 OC
(3,600 OF).
Aluminum
Melting point 660 OC
(1220 OF)
 Whatever welding methods you use: Clean the aluminum.
This is probably the most important part of welding aluminum. EVEN ALUMINUM THAT LOOKS
BRAND NEW AND CLEAN IS ACTUALLY DIRTY. IT’S NOT LIKE STEEL. This is how to prepare
aluminum for welding:

• First, clean the aluminum with acetone. Don’t use brake cleaner unless it is 100% acetone. NB:
Acetone is highly flammable so be careful, and remove it from the weld location after use. Also make
sure to have adequate ventilation/ fume extractor during the cleaning process.
• Then, rinse the aluminum using distillated water, just in case there is any residues. In tap water there
might be free iron that will contaminate the surface. The aluminum should be completely dry before
welding.
• Then, use a stainless-steel brush (make sure the brush is stainless) and scrub the aluminum shiny
clean around the area to be welded. Avoid touching the cleaned surface with your bare hands.
Start welding as soon as possible after cleaning. If you do not weld on the aluminum immediately after
cleaning, you should give it a touch up cleaning before you start to weld.

Clamp your work to a heatsink made of copper or aluminum whenever possible. Aluminum
transmits heat very well. Once the area you weld gets hot enough to melt, the rest of the work is likely
to be so hot that it is shrinking and warping. Using a heat sink under the area being welded will absorb
some of the heat and help keep the work from warping.

Preheat before welding. This makes it a LOT easier to weld aluminum. Recommended
preheating temperatures range from 135 OC (275 OF), to 260 OC (500 OF). NB. Aluminum does not
change colour while being heated.

Welding methods.
Aluminum can be welded using Gas Welding, Brazing/ Soldering, Electrode/Stick welding, TIG welding
or MIG welding. In production welding a number of other welding methods are available. In the
following we will only talk about welding methods that are available to the crew onboard in connection
with maintenance welding.
Gas Welding
Gas welding aluminum is demanding and require good understanding of the material, skill, proper
equipment and consumables. Onboard most vessels Oxy acetylene gas welding equipment will be
available. Select a welding neck according to 100L per mm material thickness. As an example, a plate
thickness of 6mm require a 600L welding neck (It will consume 600L Oxygen and 600L Acetylene per
Hour). Aluminum from 2mm (5/64”) to 10mm (25/64”) thick may be gas welded. Thicker material is
seldom gas welded, as heat dissipation is so rapid that it is difficult to apply sufficient heat with a torch.
When compared with arc welding, the weld metal freezing rate of gas welding is very slow. The heat
input in gas welding is not as concentrated as in other welding processes and unless precautions are
taken greater distortion may result.

Before you start welding, you need to find yourself the appropriate welding rod. In most cases a TIG
rod is a good choice because it is easy to find and its high purity makes for a high-quality weld. It is
worth mentioning that some prefer to use flux-cored aluminum welding electrodes (intended for
Electrode/stick welding) as it is already having a flux. Aluminum TIG rods comes in a variety of types
and diameters and can normally easily be found. In most cases type 1100 or 4043 will work well for
most applications encountered. The 1100 has properties that make it suitable for “soft” applications
where bending or shaping of metal will occur. At the other end 4043 works well for “hard” applications
where the base metal is not intended to flex. Selecting rod diameter is more of a guessing game. Start
with 2mm (5/64”) rod and move up or down in size as needed.

As mentioned previously: Clean all dirt, oil, paint, or other residue from the area to be repaired by
aluminum Gas Welding. Note previous chapter: “Clean the aluminum”.
Aluminum welding flux is designed to remove the aluminum oxide film and exclude oxygen from the
vicinity of the puddle. The fluxes used in gas welding are usually in powder form and are mixed with
distillated water to form a paste. The flux should be applied to the seam and rod by using a brush.

Direction of travel

A neutral or slightly Carburising flame is recommended for Gas welding aluminum. Oxidizing flames
will cause the formation of aluminum oxide, resulting in poor fusion and a defective weld. Start by
preheating the joint to be welded. Unlike with other metals there is no change in colour when
aluminium is heated to its welding temperature. The following tests should therefore be made to
determine if the aluminium is ready to start welding: Using a wooden stick, rub the end of the stick on
the metal being heated. At the proper temperatures, the stick will char. Start welding by passing the
flame in small circles over the starting point until the flux melts. The filler rod, coated with flux should
be scraped into the surface at three or four second intervals, permitting the filler rod to come clear of
the flame each time. The scraping action will help removing the oxides and revealing the aluminum.
The base metal must be melted before the filler rod is applied. Leftward welding also referred to as
forehand welding is generally considered best for welding on aluminum, since the flame will preheat
the area to be welded. In welding thin aluminum, there is little need for torch movement other than
progressing forward. On material 5mm (3/16”) thick and over, the torch should be given a uniform
lateral motion. This will distribute the weld metal over the entire width of the weld. A slight back and
forth motion will assist the flux in the removal of oxide. The filler rod should be dipped into the weld
puddle periodically, and withdrawn from the puddle with a forward motion. This method of withdrawal
closes the puddle, prevents porosity, and assists the flux in removing the oxide film.

The aluminum welding fluxes contain chlorides and fluorides. In the presence of moisture, these will
attack the base metal. Therefore, all flux remaining on the joints after welding must be completely
removed. If the weld is readily accessible, it can be cleaned with boiling water and a fine brush. Parts
having joints located so that cleaning with a brush and hot water is not practical may be cleansed by
an acid dip and a cold or hot water rinse. Use 10% sulfuric acid cold water solution for 30 minutes or a
5% sulfuric acid hot water at 65ºC (150ºF) solution for 5 to 10 minutes for this purpose.

NB. Regarding flux used in Gas welding and brazing processes: According to the European CLP
regulation, toxic substances such as boric acid and borax have been re-classified and categorized as
toxic to reproduction “can affect fertility and can damage the child in the mother‘s womb”. Flux and flux
coated brazing rods are therefore to be boric acid and borax free. (REACH-compliance).

Recommended filler and flux: Unitor Alumag 235 (AWS A5.10 ER 5356) + Aluflux 234F
Brazing/Soldering
Brazing and Soldering of Aluminum is accomplished with the same type of torch and gases used for
Gas welding. Some fillers can also be used using TIG welding. For soft soldering, a soldering iron
might be used. Brazing and Soldering are considered easier than Gas welding.

Brazing is a joining method which provides a permanent bond between the parts to be joined with the
help of a brazing filler metal. The composition of the filler alloy is such that its melting point is slightly
below the melting range of the parent metal of the parts. Brazing is distinguished from welding by the
fact that the parent metal does not melt during the process.

First let us clarify the difference between Brazing and Soldering. By accepted general definition of
DVS (Deutscher Verband für Schweißtechnik, Düsseldorf) the working temperature for brazing is
above 450°C (842°F), whereas it is below 450°C (842°F), in the case of soldering. Soldering is
sometime referred to as Soft Soldering. (Note: 800°F, resp. 426°C, by definition of the American
Welding Society). Brazing creates a stronger bond, but soldering is preferred for pieces with electrical
circuits or other delicate materials.

Also brazing and soldering filler alloys are classified by a number system American National
Standards Institute (ANSI). Generally, brazing of the various aluminum alloys is restricted by the
available filler alloys which are based on the binary system Aluminum - Silicon. Typical filler alloys are:

Aluminum 86%, Copper 4%, Silicon 10%. Solidus 521°C (970°F), Liquidus 585°C (1085°F). AWS &
International standards: BAISi-3, AMS 4184, AA 4184

Aluminum 88%, Silicon 12%. Solidus 577°C (1070°F), Liquidus 582°C (1080°F). AWS & International
standards: BAISi-4, AMS 4185, AA 4047

Recommendation:

Castolin Eutectic 190

Low-melting temperature alloy for capillary brazing of aluminum. Profiles, tubes, air conditioning
equipment, heat exchangers. Castolin 190 can be used in conjunction with the Oxyacetylene and TIG
processes. An aluminum silicon alloy producing good strength joints and good resistance to corrosion.
Not suitable for parts requiring anodised finishes or aluminum alloys containing more than 1.5%
magnesium. Use together with EutecTor Flux 190. Highly reactive flux for torch brazing of aluminum
and aluminum alloys. The flux is particularly suitable when brazing such common grades as 11xx,
4xxx and selected 5xxx alloys

NB. Alloys of type 2XXX and 7XXX are, not normally braze-able as their solidus/liquidus temperature
are too low for the filler metals. Alloys with higher magnesium content (> 1 - 2 %) are also difficult to
braze due to increased oxide layer formation which cannot effectively be removed by fluxes. Add flux
by dipping the filler rod into the flux or paint it on to the filler using a brush. You may also use flux-
coated or flux cored rods to eliminate this step. The flux-coated/ flux cored rods apply the flux during
the aluminum brazing process. Avoid solders that contain lead and cadmium whenever possible.

As mentioned previously: Clean all dirt, oil, paint, or other residue from the area to be repaired by
aluminum brazing. Note previous chapter: “Clean the aluminum”.

The joint designs used for brazing/ soldering aluminum assemblies are similar to those used with other
metals. The most commonly used designs are forms of simple lap and T-type joints (capillary joints).
Joint clearance varies with the specific soldering method, base alloy composition, solder composition,
joint design, and flux composition employed. However, as a guide, joint clearance ranging from 0.10 to
0.50 mm (0.005 to 0.020 “). Joints must fit snugly, but not so snug that the solder cannot get into the
gap.
Use a brush to apply the flux appropriate to the temperatures and the metal. An all-purpose flux covers
a wide range of temperatures and is beneficial to have on hand for general purpose brazing. Brazing
fluxes can start to melt and dissolve oxides already at 320°C (600°F). Heat the repaired area with an
acetylene or propane torch until the aluminum shows an orange bloom. This happens when the metal
gets very hot. Once you apply a flux, it should change colors or turn clear throughout.

NB. Aluminum parts at brazing temperatures becomes soft. As the assembly to be brazed will be
subjected to the pressure of its own weight and to the pressure of the gases emerging from the torch,
in particular long horizontal section must be supported, otherwise they will sag.

Apply the filler metal by running a brazing rod along the crack or the joint. The heat of the metal will
melt the filler into the area needing the repair. Move the flame of the torch on and off as needed to
melt the rod.

Remove the flux after the filler material has solidified by dipping the part or pouring hot water on the
repair. The flux will flake off. If it does not come off, use a stainless-steel wire brush to gently scrub the
brazed area while wet or still in the hot water.
Electrode/Stick Welding
Prior to the development of the inert gas welding process (TIG & MIG) the arc welding of aluminum
was mainly restricted to the Electrode/Stick Welding (Shielded Metal Arc Welding SMAW) also
referred to as the Manual Metal Arc Process (MMA). This welding process uses a flux-coated welding
electrode.

The electrodes are straight lengths of aluminum rod, coated with flux. The flux acts to dissolve the
aluminum oxide on both the base alloy and the rod during welding, which is necessary if coalescence
is to occur. Some of the flux components vaporize in the arc to form shielding gases that help to
stabilize the arc and shield both it and the weld pool from the surrounding atmosphere. There are
however a number of problems related to Aluminum Stick/Electrodes. First, they are not 100%
effective, so most aluminum shielded metal arc welds suffer from a large amount of porosity. Second,
they are very hygroscopic, so they require good storage practices so they do not absorb water vapor
from the air. Third, the solidified flux is corrosive to aluminum and other materials. If it is not completely
removed from the weld after welding, it can cause corrosion in a short period of time. Fourth, the flux is
corrosive and environmentally unfriendly. Last, while aluminum is chemically active, magnesium is
even more active, which makes it difficult to shield aluminum/magnesium filler alloys with a flux. In
fact, the only available aluminum stick electrodes are of the 4043 types with silicon added. Most
common size of stick welding electrodes are 3,2mm (1/8”)

There are no electrodes available for the high magnesium content base alloys and electrodes, once
exposed to the air, begin to absorb moisture into the flux, which eventually corrodes the aluminum
core and produces excessive porosity problems.

Electrode/Stick welding does have an advantage over TIG and MIG welding: The equipment needed
is significantly cheaper and less complicated than that used for TIG or MIG welding. All that you need
is an inexpensive Direct Current Electrode/Stick welding machine—no gas bottles, torches, regulators,
or other related equipment.

As mentioned previously: Clean all dirt, oil, paint, or other residue from the area to be repaired by
welding. Note previous chapter: “Clean the aluminum”. Preheat before welding. This makes it a LOT
easier to weld aluminum. Recommended preheating temperatures to 260 OC (500 OF).

The welding machine must be a Direct Current (DC) power source. Connect electrode/ electrode
holder to plus (+) polarity on welding machines front panel. The reason for doing this is that electrons
moves from minus to plus polarity. If the return (-) is connected to the work peace the electrons will
brake trough the oxides on their way to the electrode tip (+)
Minus polarity and the flux coating on the electrode helps to break up the oxides but it is still a difficult
task to observe and control the weld pool.

Another thing that helps is to tilt the electrode approximately 10O in the direction of travel. This will
make the flux run in forefront of the pool and help dissolving the oxide layer

Direction of travel Tilt electrode 10O in

direction of welding

Aluminum electrodes are not environmentally friendly so make sure to have good ventilation and avoid
inhalation of the welding fumes. Preferably have a fume extractor available during welding. Remember
to remove all solidified flux (slag) after welding. As mentioned before: If it is not completely removed
from the weld after welding, it can cause corrosion in a short period of time.

Recommended electrodes: Unitor Alumin-351N in 3,2mm. The electrode is alloyed with 12% silicon.
This is an electrode primarily for welding of cast aluminum alloys but can also be used to weld rolled
alloys and for joining cast to rolled alloys. If the aluminum base material is of unknown composition
this electrode gives the best chance of success.

Aluminum electrodes
should preferably be
vacuum packed to stop
moisture pick up

Esab OK 96.20 is an aluminum electrode alloyed with a 1% manganese addition usually used for
welding of rolled weldable aluminum magnesium and aluminum manganese alloys.
Esab OK 96.40 is an aluminum electrode alloyed with 5% silicon. This is suitable for welding AlMnSi
alloys such as AWS 6060/6063, 6005 and 6201. It can also be used to weld AlSi5Cu and AlSi7 cast
materials.
TIG Welding
The most applicable and best process for maintenance and repair welding of Aluminum is TIG
welding. Tungsten Inert Gas (TIG) welding also known as Gas tungsten arc welding (GTAW), is an arc
welding process that uses a non-consumable Tungsten (Wolfram) electrode to produce a weld pool.

1 Short back-cap or...

2 Long back-cap
2 3 Heat shield
4 Collet 1.6mm
4 Collet 2.4mm
5 Collet body 1.6 mm
3 Alternative: Gas Diffuser
5 CoIlet body 2.4 mm
Alternative: Gas Diffuser
6 Alumina nozzle 6
7 6 Alumina nozzle 7
4 6 Alumina nozzle 8
7 Tungsten electrode 1.6 mm
7 Tungsten electrode 2.4 mm
5

TIG welding is most commonly used to weld thin sections of stainless steel and non-ferrous metals
such as Aluminum and seawater resistant alloys like Cunifer and York Albro. The process grants the
operator greater control and accuracy over the weld compared to other processes, allowing for
stronger and higher quality welds. The welding technique is similar to gas welding (Leftward welding/
forehand welding).

Direction of travel

For TIG welding Aluminum the tungsten electrode tip is grinded to a round shape. The arc and the
electrode are shielded by an inert gas (normally Argon) that also surrounds the weld pool and prevents
oxidation. TIG welding of aluminum must be performed with a AC current welding machine. The
reason for using Tungsten is that it has a very high melting point of 3000 OC (5432OF). Tungsten
electrodes are normally available in two different diameter sizes, 1,6mm (1/16″) or 2,4mm (3/32″).
During TIG welding the tungsten electrode will not melt despite very high temperatures, but it will
gradually be consumed during ignition and to some extent during actual work. This is referred to as the
burn-off rate. In time, it will be necessary to regrind the electrode.

In order to extend their capacity and performance the manufacturers alloy in any of the following
elements: Cerium, Lanthanum, Zirconium or Thorium.

NB. Thoriated TIG welding electrodes with 2% thorium oxide (color code red) are currently the most
widely used electrodes worldwide. Thorium is however a radioactive element and as such represents a
potential danger to health and environment. Thorium is a so-called “a-emitter,” but when enclosed in a
tungsten matrix, the “a” radiation emitted externally is negligible. The danger to the welder arises when
thorium oxide gets into the respiratory canals. This problem can occur during welding (vapors) as well
as when grinding the electrode tip (grinding dust). It is expected that TlG-welding electrodes containing
thorium will disappear from the market in the future, especially as an environmentally friendly and
technically better solution is already available.

Recommendation: Tungsten electrodes alloyed with Lanthanum (color code gold) can be used for AC
and DC welding.

Aluminum is an excellent conductor of heat. It requires large heat inputs when welding is begun, since
much heat is lost in heating the surrounding base metal. After welding has progressed a while, much of
this heat has moved ahead of the arc and pre-heated the base metal to a temperature requiring less
welding current than the original cold plate. If the weld is continued further on to the end of the two plates
where there is nowhere for this pre-heat to go, it can pile up to such a degree as to make welding difficult
unless the current is decreased. Because of this the TIG torch should be fitted with a hand amperage
control so that the welder can gradually reduce the amperage.
To better understand why, it is necessary to use Alternating current, preferably square wave when
welding Aluminum consider the following:

DC
TIG welding using Direct Current
(DC) minus polarity the electrons
bombard the aluminum melting it,
but are unable to brake the
oxides

AC SQUARE
TIG welding using Alternating
WAVE Current (AC) the polarity change
from minus to plus. During minus
it melts the aluminum, during plus
it breaks up the oxides

So, the Polarity is important

With AC, during the half cycle when the electrode is positive and the workpiece is negative, the
electrons coming out of the workpiece break up what is left of the oxide layer: this action is known as
cathodic cleaning and is essential for successful Welding-aluminum.

To avoid torch overheating new power sources for TIG welding have square wave configurations
where both the time proportions of electrode positive vs. negative and the relative intensities can be
finely adjusted. The effect is a more stable arc (than with simple AC), better penetration, and a more
balanced heat distribution between torch and workpiece. Recommended machine is Unitor UWI-230
TP AC/DC that provide square wave ability and turbo effect where time proportion of electrode positive
is increased thereby increasing the heating period, and hence the welding speed. Avoid using welding
machines with Open Circuit Voltage (OCV) above 25V or that depend on High Frequency.

For maintenance welding an air cooled TIG torch will normally be sufficient. If extensive welding
considers a water cooled TIG torch. It will be an advantage if the TIG torch is fitted with a thumb
control amperage setting so that amperage can be increased or decreased during welding.

Fit the TIG torch with a pure tungsten (color code green) or with Lanthanum (color code gold)
electrode for aluminum welding if you have a non-square wave welding machine.

Fit the TIG torch with a Lanthanum (color code gold) tungsten electrode for aluminum welding if you
have a square wave welding machine

The TIG torch should preferably be fitted with a gas diffuser (sintered metal) in order to avoid
turbulence in the shielding gas as it comes out of the TIG torch.

The TIG torch alumina nozzle must be size 8. This because the aluminum molten pool need better
protection towards oxidation than steel or stainless steel.

Adjust the tungsten to project from the alumina nozzle a distance roughly equal to the diameter of the
tungsten.

Use a 1,6mm (1/16″) tungsten electrode for 30 to 80 amps

Use a 2,4mm (3/32″) tungsten electrode for 80 to 180 amps
Use a 3,0mm (1/8″) tungsten electrode for anything above 180 amps

Use Argon quality 4.0 (99,99) and flow rate 6 to 9 L/min.

The arc length should be roughly equal to the diameter of the tungsten.

Use a filler rod size equal to the tungsten size. Recommended filler: Unitor Alumag 235 (AWS A5.10
ER 5356).

As mentioned previously: Clean all dirt, oil, paint, or other residue from the area to be repaired by TIG
welding. Note previous chapter: “Clean the aluminum”.
MIG Welding
Metal Inert Gas (MIG) process, or sometime referred to as Gas Metal Arc Welding (GMAW) are a Wire
Welding process. Wire Welding is a process where a wire from a reel is fed through a welding torch
passing a contact tip supplying the welding current. The wire melts and is transferred to the pool
through the arc. A shielding gas (Argon) is necessary to prevent oxygen oxidising the pool.

Power-source selection: When selecting a power source for MIG welding of aluminum, first consider
the method of metal transfer -spray-arc or pulse. Constant-current (cc) and constant-voltage (cv)
machines can be used for spray-arc welding. Spray-arc takes a tiny stream of molten metal and
sprays it across the arc from the electrode wire to the base material. For thick aluminum that requires
welding current in excess of 350 A, cc produces optimum results.

Pulse transfer is usually performed with an inverter power machine. Newer power supplies contain
built-in pulsing procedures based on filler-wire type and diameter. During pulsed MIG welding, a
droplet of filler metal transfers from the electrode to the workpiece during each pulse of current. This
process produces positive droplet transfer and results in less spatter and faster follow speeds than
spray-transfer welding. Using the pulsed MIG welding process on aluminum also better-controls heat
input, easing out-of-position welding and allowing the operator to weld on thin-gauge material at low
wire-feed speeds and currents.

Some of the inherent problems associated with MIG welding of aluminum, compared to the welding of
steel, are: feed ability, incomplete fusion at the start of a weld, and crater or termination cracking at the
ends of the weld.

Feed ability is the ability to consistently feed the spooled welding wire when MIG welding, without
interruption. Feed ability is probably the most common problem experienced when moving from MIG
welding of steel to MIG welding of aluminum. Feed ability is a far more significant issue with aluminum
than steel. This is primarily due to the difference between the materials' mechanical properties. Steel
welding wire is rigged, can be fed more easily over a further distance and can withstand far more
mechanical abuse when compared to aluminum. Aluminum is softer, more susceptible to being
deformed or shaved during the feeding operation, and, consequently, requires far more attention when
selecting and setting up a feeding system for MIG welding. NB. 4043 filler wire is a softer alloy in the
form of spooled wire, compared to 5356. Typically, when MIG Welding, feed ability will become a less
critical issue when feeding the more rigid 5356 alloys.
Recommended filler: Unitor Alumag W-235 (AWS A5.10 ER 5356) 1mm

Feed ability problems often express themselves in the forms of irregular wire feed or as burn-backs
(the fusion of the welding wire to the inside of the contact tip). In order to prevent excessive problems
with feed ability of this nature, it is important to understand the entire feeding system and its effect on
aluminum welding wire.

Starting with the spool end of the feeding system, the brake settings must be considered first. Brake
setting tension, is required to be backed off to a minimum. Only sufficient brake pressure, to prevent
the spool from free-wheeling when stopping welding, is required. Electronic braking systems and
electronic and mechanical combinations have been developed to provide more sensitivity within the
braking system.

Brake setting tension

Inlet and outlet guides, which are typically made from metallic material for steel welding, should
preferably be made from a non-metallic material such as nylon to prevent contamination, abrasion and
shaving of the aluminum wire. It is also very important that the outlet guide is placed as close to the
drive roll as possible to catch the wire as it comes off the drive roll.

As close to drive roll as possible

Outlet guide
Liners, which are typically made from metallic material for steel welding, must be made from a non-
metallic material such as Teflon or nylon to prevent contamination of the aluminum wire. Do not use
steel liners that will contaminate the aluminum wire. Change liners with regular intervals to avoid build-
up of aluminum oxide that interrupt consistently feed.

Teflon Liner

Steel Liner

For a gas cooled MIG torch, it is better use a Teflon liner with a short bronze liner at the end towards
the torch neck. This is because a Teflon liner could be overeating near the torch neck/contact tip and
melt

Bronze Liner

Teflon Liner with Bronze end

.
Drive rolls have been developed, often with U-type contours with edges that are chamfered and not
sharp, that are smooth, aligned, and provide correct drive roll pressure. Excessive drive roll pressure
can deform the aluminum wire and increase friction drag through the liner and contact tip.

Excessive
drive roll
pressure

U-groove for
aluminum

Contact tip Internal Diameter (I.D.) and quality are of great importance. As current are put to the wire
in the contact tip the aluminum wire’s thermal expansion (which is about twice that of steel) will make it
expand and get stuck in the contact tip. It is therefore important that the contact tips ID is bigger than
the wire diameter. For example, a 1mm (0,039”) aluminum wire should be used with a 1,2 mm (0.047”)
contact tip.

(1) Torch handle (Gun)

(2) Insulator
(3) Shielding gas diffuser,
(4) Contact tip,
(5) Gas nozzle

Contact tips made specifically for aluminum welding are available, with smooth internal bores and the
absence of sharp burrs on the inlet and outlet ends of the tips which can easily shave the softer
aluminum alloys.
Special contact tips for aluminium:

Without ‘A’ For carbon steel and

stainless steel
Ø1.0 mm (0,039”)

With ‘A’ Only for aluminum wire

Ø1.0 mm (0,039”)

Without ‘A’
For carbon steel and
stainless steel

Ø1.2 mm (0.047”)

With ‘A’ Only for aluminum wire

Ø1.2 mm (0.047”)

Generally, when a welding current exceeds 200 A use a water-cooled gun to minimize heat build-up in
order to further reduce wire-feeding difficulties.

Special Features for Welding Machines for Aluminum Welding:

The Hot Start Feature: Aluminum has a thermal conductivity about six times that of steel, and
because of this ability to rapidly conduct heat away from the weld area, there has always been an
inherent problem, particularly when starting a weld on this material. It is not uncommon to experience
incomplete fusion at the start of an aluminum weld because of the material's high thermal conductivity.
One method which can now be used to help overcome this problem, particularly on thicker sections of
aluminum used in structural applications, is the use of equipment that has a hot start feature. This
feature may allow the user to program the weld starting current characteristics independently from that
of the general welding current parameters, thus providing the user with the ability to start the weld with
a higher current density for a predetermined period before moving to the general welding conditions
for the remainder of the weld. This allows the use of a higher heat input at the beginning of the weld
that can help to overcome the dramatic heat sink associated with this material prior to the weld area
becoming heated by the welding operation. The result of this technique is to eliminate, or significantly
reduce, the probability of incomplete fusion at the start of the weld and thereby improve the life
expectancy of welded components.

Crater Fill Feature: Other characteristics of aluminum that can provide welding problems are
associated with its thermal expansion (which is about twice that of steel) and its shrinkage on
solidification (which is 6% by volume). This can increase both distortion and weld crater size. One
common concern when welding aluminum is crater cracking or what is sometimes called termination
cracking. When MIG welding with conventional equipment, once the trigger of the welding gun has
been released, the arc is extinguished, and no additional filler metal is added to the weld pool to fill the
crater. Consequently, if no further precautions are taken, a large crater will be left which will have a
higher probability of cracking. Craters can be serious defects, and most welding standards require
them to be filled and free from cracks. Run-off tabs or other methods of locating weld craters on scrap
material away from the weld are not usually practical. However, if the weld pool size can be reduced
before the arc is fully extinguished, the resulting crater may be very small or almost eliminated and,
consequently, the weld may be free from cracks. In the past, a number of welding techniques have
been used in an attempt to reduce this termination problem. Reversing the direction of travel at the
end of a weld, increasing travel speed to reduce crater size, and providing suitable build-up and
remoulding the crater area flush with the weld surface by mechanical means are some of the methods
which have been used. These methods are often difficult to control, require specialized training, and
are not always successful in their objective. More recently, welding equipment has been developed for
aluminum welding which has a built-in crater fill feature. This feature is designed to terminate the weld
in a gradual manner by decreasing the welding current over a predetermined period as the weld is
completed. This feature may be adjustable to enable the user to select the most favourable
termination conditions and thereby prevent a crater from forming at the weld termination. Tests have
shown this crater fill feature to be extremely user friendly and very effective in eliminating the crater
cracking problem.”

Recommended welding machine for MIG aluminum welding: Weco Micro Pulse 302MFK. This is a 3-
phase robust designed Inverter for Synergic, Pulse Synergic and Double Pulse Synergic MIG/MAG
welding, MMA and TIG Lift Arc welding. Easy to transport, compact and only 24kg, it is a most suitable
machine for maintenance and repair welding of aluminum onboard. It can also with good results be
used for other metals like steel and stainless steel.

Alternative if only 1 phase 230 V available onboard: Unitor UWW-161 TP. This is a standard all-round
welding machine that are not specifically meant for aluminum. It can however be modified for
aluminum welding by fitting the machine with a Spool gun. In a Spool gun the wire spool and the wire
feed mechanism are moved out on the gun itself thereby creating a short and steady wire feed.

Euro connector Wire drive 4 inch aluminum wire spool

Shielding gas for aluminium: Argon (quality 4.0 (99,99%) due to its good cleaning action and
penetration profile, is the most common shielding gas used when welding aluminum. Welding 5XXX-
series aluminum alloys, a shielding-gas mixture combining argon with helium – 75% helium maximum
- will minimize the formation of magnesium oxide. Argon flow rate start at 25 L/min.,

Welding wire: Select an aluminum filler wire that has a melting temperature similar to the base
material. The more the operator can narrow-down the melting range of the metal, the easier it will be
to weld the alloy. The larger the wire diameter, the easier it feeds.

Clean the aluminum: Clean all dirt, oil, paint, or other residue from the area to be repaired by MIG
welding. Note previous chapter: “Clean the aluminum”.

Welding technic: Point the gun slightly in the direction of travel.

Direction of travel

NB For TIG and MIG Welding: Make sure that the welding location is screened off towards wind and
draft that can interrupt the shielding gas and cause porosity.

To sum up:
Clean the aluminum and preheat before welding. TIG welding is undoubtedly the best way for
performing maintenance welding of aluminium. MIG welding is easy, fast and efficient but, you need a
lot of welding work to justify the investment in equipment. Stick / electrode welding and gas welding
can make use of existing and traditional equipment but require a highly skilled welder.