Welding of aluminium and aluminium alloys
Aluminium and its alloys are widely used in the manufacture of structural components and consumer products due to their remarkable physical properties, cost-effectiveness, recyclability and corrosion resistance. However, these materials can be challenging to weld due to their thermal-mechanical and reactivity properties. This article provides an introduction to the principles and processes of welding aluminium and its alloys and outlines the benefits of each type of welding process.
Arc welding is the most common method of joining aluminium and its alloys. Gas tungsten arc welding (GTAW or TIG) is generally preferred for welding thin components such as tubing and piping, as it is easy to control and allows precise manipulation of the heat input. Heat input is a critical factor for welding aluminium since excessive heat can distort the workpiece and cause cracking; this makes GTAW the ideal process for aluminium welding due to its low heat input and precise control. MIG/MAG welding (wire feed) is also widely used for welding aluminium and its alloys, and is typically used to weld thicker components such as industrial tanks and frames.
Aluminium can also be welded using brazing and soldering processes. Brazing is the preferred method for joining thin sheets of aluminium, as the heat input is relatively low and the process is less likely to cause distortion. Soldering is also suitable for aluminium welds but is not typically used as it has a limited melting temperature range and can be difficult to control.
Resistance welding and laser welding are also used for welding aluminium and its alloys but are relatively uncommon due to the high cost and complexity of the process. Resistance welding is typically used for welding aluminium wire and other small components and laser welding is used for joining thin sheets and components with complex geometries.
To conclude, there are a range of processes that can be used to weld aluminium and its alloys. Arc welding is the most common method, but brazing and soldering can also be used for certain applications. Resistance welding and laser welding can also be used but are significantly more expensive and complex than the other methods. It is important to choose the most appropriate welding process for each application in order to achieve the best results.
