Aluminium Sheet Welding

To prevent burn through and warping don t whip or weave the torch.

Aluminium sheet welding.

It is recommended that a welder should use 023 or 024 inch wire for light gauge sheet metal work. Filler metals for either of these would be 4043 or 4943. It may take some practice so here are some tips for welding aluminium. Another rule of thumb for tig welding sheet metal thicknesses is try not to use a filler rod that is thicker than the metal you are welding.

Aluminum welding needs to be performed hot and fast unlike steel the high thermal conductivity of aluminum dictates use of hotter amperage and voltage settings and higher weld travel speeds. Techniques for welding sheet metal. Thick can present numerous problems such as bum through and tough starts. Mig gmaw welding the most popular welding machine in the collision repair shop by far is the mig welder.

High weld speed and low distortion properties on steel sheet have ensured its home in these shops when used properly. A 5356 filler metal also works for 5052 materials specifically. Using too small a filler rod can be a problem too. If travel speed is too slow the welder risks excessive burnthrough particularly on thin gage aluminum sheet.

However if you are dealing with materials that are 18 gauge or thicker one should be able to use 030 inch welding wire. Typical aluminum alloys for sheet fabrication are 3003 and 5052. Welding aluminium is just different from welding steel. Aluminum is a lightweight soft low strength metal that can easily be cast forged machined formed and welded.

Welding aluminum is not as hard as you think. This instructable will teach you how to use a propane torch and some aluminum brazing rods as a quick way to bond aluminum without using a welder. Aluminum is readily joined by welding brazing and soldering. I used 1 16 1 6m 4043 rod for this outside corner joint in 040 and it worked out ok.

Aluminum is quite reactive so forms an oxide layer when it s exposed. However aluminum sheet less than 1 8 in. As a rule when mig welding sheet metal never use a body filler metal that is thicker than the base metal. The more time the arc is in an area the hotter it.

Turns out you can weld aluminum without a welder. But that is only a guideline. Unless alloyed with specific elements it is suitable only in low temperature applications. But first a word about safety before you start welding make sure the area is well ventilated.