Aluminum in its pure form is a relatively soft metal that has many uses, but which requires the addition of an alloy or alloys to increase its strength and to add other qualities suitable for different applications. Common alloys are: copper, magnesium, silicon, manganese and zinc. They are identified by their series numbers:
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Aluminum, especially thin-gauge aluminum, presents some unique welding challenges. For many, GTAW is the preferred process, but GMAW offers some obvious benefits: higher deposition rates, less operator training and higher productivity. With these benefits come a few challenges, namely wire feeding and selecting the right type of filler metal and equipment. These challenges can be easily met, however, by knowing the answers to some common questions.
While filler metal for steel is typically chosen by matching the tensile strengths, strength is only one of the considerations when choosing an aluminum filler metal. Typically, there are several different aluminum filler metals that would be acceptable to use when welding aluminum base materials. In choosing a filler metal, consider:
-Base metal composition
-Ease of welding
-Joint design
-Dilution (when the filler wire and base metal combine in the weld puddle to create a different chemical make up in the weld)
-Strength of the weld
-Hot cracking sensitivity
-Ductility
-Corrosion in service
-Color matching, if the material is anodized
-Elevated service temperature (150-350 Fahrenheit)
Different filler metals address these considerations to varying degrees. In general, if strength is the primary consideration, the filler metal should closely match the base metal in tensile, yield and ductility.
Most consumable manufacturers, as well as the American Welding Society (AWS), offer information listing the relative values of these considerations of their filler metals for each base alloy. Always make sure to use an aluminum filler metal selection chart to address the weld properties listed above.
Traditionally, welders have relied on AWS and wires, as they can be used with the most widely used aluminum alloy base metals. Hobart, however, offers an alternative to filler metals to increase strength and quality. The MaxalMig® aluminum wire offers approximately 20% higher tensile strength and doesn’t rely on diluting the aluminum base material to gain strength. This feature often allows welders to make smaller, single-pass welds and still get reliable strength. It also helps minimize the risk of distortion since heat input is lower.
Aluminum as a filler metal has the same oxidation problems as all aluminum. When left open, either on the shelf or installed on the welder, aluminum filler wire will oxidize, which can lead to an erratic arc. The oxidation adds resistance, can produce smut and can change the wire’s ability to feed smoothly. Many operators have spent a great deal of time adjusting tension settings, changing contact tips or checking the shielding gas trying to fix the problem when it was the oxidized wire that was at fault.
Because of its low columnar strength, feeding aluminum wire has been likened to pushing a wet noodle through a straw. Birdnesting, or the tangling of the wire between the drive roll and the liner, is a common, time-consuming and costly problem. Clearing it requires the operator to stop welding, cut the wire, discard the wire in the gun and re-feed new wire through the liner. It also may require cleaning or changing the contact tip because of the burnback caused when the wire stops feeding.
There are several ways to feed aluminum wire: Push only, spool gun, push-pull system and continuous feed push-only system.
Push only: Feeding aluminum wire through a push-only system can be difficult, but it can be done on a limited basis. It requires u-groove drive rolls to provide more surface contact with the wire, adequate drive-roll pressure and the ability to keep the gun cable straight. Any resistance in the line will likely cause the wire to misfeed. Thicker wire, such as 1/16 inch, may be fed consistently in a push-feed system. But for thinner gauges, such as .030 inch, push feeding is not very dependable.
Spool gun: Welding aluminum with a spool gun, such as the Spoolmate™ or Spoolmatic® series of guns, eliminates the possibility of birdnesting by putting a 4-inch (1-pound) spool on the gun, so the wire only feeds a few inches. Spool guns can accommodate aluminum wire diameters from .023 to 1/16 inch and allow the operator to use longer cables (15-50 foot).
A spool gun needs to have the roll changed after every pound of wire is used, compared with the 16- or 22-pound spool on a push-pull system. In tight spaces, the spool may limit access, requiring the operator to use a longer stickout. If the operator is using several pounds of aluminum per day, the few minutes needed to change spools can add up. Also, the chance of burnback exists when the end of a spool is reached, so many operators stop when a few turns are left on the spool.
Push-pull gun: With a push-pull gun, a motor in the gun pulls the wire through the liner, while the motor in the welder or feeder control becomes an assist motor. By maintaining consistent tension on the wire, the push-pull system helps eliminate birdnesting. It is more ergonomic than the spool gun since the weight of the spool is not in the operator’s hands.
Also, the spool needs to be changed less often than on a spool gun and allows the purchase of larger spools. A push-pull gun also allows cables up to 50 feet long. The only disadvantage to push-pull systems is their relatively higher price tag, but the increased productivity and the financial advantage of buying larger spools usually provide a quick return on investment. When you compare the cost of 16 1-pound spools of .035-inch aluminum filler wire with one 16-pound spool of the same diameter wire, plus the time to change 16 spools versus one spool, you’ll see that for high-volume use, a push-pull system makes financial sense.
A welding distributor, picked at random, lists a price for a 1-pound spool of .035-inch aluminum wire as $11.46. A 16-pound roll lists for $170.24, which works out to a difference of $0.82 per pound. Now, add the time for 16 spool changes (and possibly burnbacks) for the spool gun as compared with one change for the larger spool. At five minutes to change a spool, that’s 80 minutes of extra time for each 16 pounds of filler wire used.
Continuous-feed push system: This is a relatively new addition to the field. This type of system uses a special drive system that maintains continuous contact with the wire and eliminates the possibility of birdnesting since there is no gap between the drive rolls and the liner. While it is limited to pushing the wire 15 feet, the gun is lighter than either the spool gun or the push-pull gun and requires no additional maintenance.
Check out this article for more MIG welding aluminum best practices.
In order to choose the right welding wire, first of all, the question must be asked - What material will be welded? Knowing the answer, you can find the most suitable welding wire! In the farm, workshop, production, various materials are used, such as - ordinary carbon steel, stainless steel, aluminum alloys, etc.
Welding materials can be divided into several groups - carbon steel, stainless and aluminum. With ordinary steel, everything is clear. Ordinary, popularly called "black steel" welds without complications. We choose welding wire with low carbon content.
Stainless steel - welding wires are selected according to metal grades (308L, 309L, 312L, 316L, 318L, etc.). Of course, metal brands can have different designations, applying different standards. EN ISO -A and AWS/ASME SFA-5.9 are more commonly used in Europe. Popular and high-quality welding wire manufacturers in the world usually indicate the designations of several standards on the package, which makes it easier for the welder to understand what material the wire is intended for.
Aluminum welding is recommended to be divided into two large groups. Casting AlSi - an aluminum body for a part, for example, a car engine body. The second group, AlMg, includes aluminum plates, tubes (everything that is not cast). Mg-Al alloys are the most widely used, they are also called magnesium alloys. Mg alloys have moderate strength, relatively high plasticity, relatively high corrosion resistance and low cost. Examples in designations: AlMg 3-ER, AlMg 5-ER, AlMg 4.5 Mn-ER, AlMg 4.5 Mn Zr-ER. Aluminum alloys with Si as the main alloying element form a class of materials that provide the most important part of all materials produced by casting. These alloys have a wide range of applications in the automotive and aerospace industries due to their excellent combination of castability and mechanical properties, as well as good corrosion and wear resistance. Examples in designations: AlSi 5-ER, AlSi 12-ER.
How to choose a welding wire manufacturer?
This question is always relevant. In different situations and circumstances, the choice may be different. A wide spectrum is available in European countries with different welding wire manufacturers. The choice of price and quality is huge. To answer the question "which welding wire should I buy?" It is necessary to firmly understand what we will weld. Is the construction to be welded one of the most responsible? Will the weld seam be durable and not endanger the environment and the people around. If these questions are positive, it is clear to choose a welding wire manufacturer with high quality and a recognizable brand. If the structure is not load-bearing and responsible, it is also possible to choose a supplier that is cheaper in terms of costs. In the Industar store, you will find an offer of welding wire manufacturers of wide application and price range.
Industar.lv the range includes all the most popular welding wire manufacturers:
Böhler WeldingMagmaweldLincoln ElectricMetaweldFarinaEsabWelding Alloys GroupNovofilGekaTecPremium PlusTelwinTorrosTemoBmwHyundai WeldingElborOerlikonHilcoDratec Drahttechnik
TORROS welding wire 0.8mm SG2, 5 kg
TORROS welding wire 0.8mm SG2, 15 kg
BMW-50 welding wire 0.8-1.2mm G3Si1 5-15 kg
TEMO welding wire 0.8-1.2mm G3Si1 5-15 kg
NOVOFIL welding wire 0.6-1.6mm G3Si1 5-15 kg
NOVOFIL welding wire 1.0-1.2mm G3Si1 15 kg Bronze
NOVOFIL welding wire 0.8-1.2mm G4Si1 15 kg
ESAB OK Autrod 12.51 welding wire 0.8-1.2mm 15-18 kg
ESAB OK AristoRod welding wire 12.50 0.8-1.2mm 15-18 kg
ESAB OK AristoRod 12.63 welding wire 1.2mm 18 kg
NOVOFIL welding wire 1.0mm G4Si1 250 kg
Contact us to discuss your requirements of Aluminum Mig Welding Wire. Our experienced sales team can help you identify the options that best suit your needs.
FARINA non-alloyed steel welding powder flux wire 0.8mm 1 kg
TELWIN non-alloyed steel welding powder wire 0.8mm 3 kg
FARINA non-alloyed steel welding powder wire 0.8mm 5 kg
TORROS E71T-11 unalloyed steel welding powder wire 0.8mm 5 kg
ESAB OK Tubrod 15.14 welding wire 1.2mm 16 kg
ESAB OK E71T-1 welding wire 1.2mm 16 kg
WELDREX stainless steel welding wire, 308LSi, 0.8mm, 1.0 kg
WELDREX stainless steel welding wire, 316LSi, 0.8mm, 1.0 kg
MTC welding wire for stainless steel MT-308L, 0.8-1.2mm 1-15 kg
MTC welding wire for stainless steel MT-309L, 0.8-1mm 5-15 kg
MTC welding wire for stainless steel MT-312, 1-1.2mm 15 kg
MTC welding wire for stainless steel MT-316L, 0.8-1.2mm 1-15 kg
NOVOFIL welding wire for stainless steel 316LSi, 0.8-1.2mm 15 kg
ESAB OK Autrod 308LSi; 316LSi welding wire 0.8-1.0mm 15 kg
WELDREX aluminum welding wire, AlSi 5, 1.0mm, 0.45 kg
WELDREX aluminum welding wire, Al Mg 5, 1.0mm, 0.45 kg
MTC aluminum welding wire MT-Al 99.5Ti, 0.8-1.0mm 2-7 kg
MTC aluminum welding wire, MT-Al Mg3, 1-1.2mm 2-7 kg
MTC aluminum welding wire, MT-AIMg 4.5Mn 1-1.2mm 7 kg
MTC aluminum welding wire, MT-Al Mg5, 0.8-1.2mm 2-7 kg
MTC aluminum welding wire MT-AlSi5 1-1.2mm 2-7 kg
MTC welding wire MT-CuSi3, 0.8-1.0mm 1-15 kg
MTC welding wire MT-Ni Mo Cr, 1.2mm 15 kg
MTC welding wire for fusion MT-HB600 1.2mm 15 kg
REMEMBER! Choosing the right type of steel welding wire is important to achieve a quality and durable weld. Some welding wire choices depend on the welding equipment the welder uses or the welding method used.
GOOD TO KNOW! Welding wires are divided into: solid and powder wires. Continuous welding wires require a shielding gas to protect the seam from the environment during welding. Powdered wires are divided into two types: using shielding gas and without gas. There can also be a different wire filling - metal, rutile, or some additional alloying element to give the seam some properties, such as wear resistance.
ON THE GAS! Shielding gas for welding is selected according to the type of welding and welding material, wire. More often, a mixture of Ar and CO2 (MISSON 18) is used for MIG/MAG welding of low-carbon steel. When welding aluminum, pure argon or helium.
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