Aluminium Sheet Welding

Techniques for welding sheet metal.

Aluminium sheet welding.

Mig gmaw welding the most popular welding machine in the collision repair shop by far is the mig welder. It may take some practice so here are some tips for welding aluminium. Aluminum is a lightweight soft low strength metal that can easily be cast forged machined formed and welded. High weld speed and low distortion properties on steel sheet have ensured its home in these shops when used properly.

Filler metals for either of these would be 4043 or 4943. 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. However aluminum sheet less than 1 8 in.

Aluminum is a lightweight thin metal which is used very commonly in welding workshops. Welding aluminium is just different from welding steel. Welding aluminum is not as hard as you think. It makes for a very strong bond and with a little practice can be done quickly with great looking results.

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. With this metal welding has to be done at low temperatures or else you will just end up blowing holes in your materials. 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. Using too small a filler rod can be a problem too.

It is recommended that a welder should use 023 or 024 inch wire for light gauge sheet metal work. The more time the arc is in an area the hotter it. Typical aluminum alloys for sheet fabrication are 3003 and 5052. Aluminum is quite reactive so forms an oxide layer when it s exposed.

Turns out you can weld aluminum without a welder. Unless alloyed with specific elements it is suitable only in low temperature applications. 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. Thick can present numerous problems such as bum through and tough starts.

I used 1 16 1 6m 4043 rod for this outside corner joint in 040 and it worked out ok. As a rule when mig welding sheet metal never use a body filler metal that is thicker than the base metal. To prevent burn through and warping don t whip or weave the torch. But that is only a guideline.