Welding Aluminum

General

• This is a self-annealing weld.
• The material can be dirty or oily.
• Welds are as strong as TIG
• No special rods or gasses are required.
• Welds 0.020 to 1/2" thick and castings up to 1" thick.

• #00 for 0.010 to 0.020
• #0 for 0.025 to 0.030
• #0.5 for 0.035 to 0.045
• #1 for 0.050 to 1/8"
• #2 for thicker than 1/8"
• #2.5 tip may be helpfull on 3/8" and thicker

• We recommend and use the TM2000 lens (see accessories). It provides best view of the weld puddle and superior eye protection. (as used in our training video)
• economical alternative lens also available.
• Standard lenses or auto-darkening will not filter out the correct spectrum of light produced by the flux.

• use 4 to 4 1/2 psi on both gases
• if a 50' hose is used, increase your pressure 1 to 2 psi (see setting up the torch )

• Use a neutral or just off feather

• Flux required - (see accessories)
• Mix with water to form paste, and coat rod sparingly.

Rod material

• Identity aluminum alloy and if possible match rod to alloy.
• 1100 (softest - best for body work or forming)
• 4043 - (most common - boats)
• 5356 - (hardest and strongest - aircraft and T-6)
• for sheet aluminum - shear small strips

When sizing your rod

• 1/16" for 0.020
• 3/32" for 0.030 to 0.040
• 1/8" for 0.050 to 1/8"
• 5/32" for thicker.

• Move torch in slow small increments - wide oscillations are not necessary.
• Do not remove flame from metal abruptly as this may crystallize the weld.
• Heat metal until puddle forms and looks like jello. Dip rod in puddle and pull out and repeat.
• On 1/16" and thicker preheating will be required.