Category: Aluminum Fabrication

Aluminum is a great material to work with when you need a metal that is lightweight, easy to cast and form, resistant to corrosion, and non-toxic. We use aluminum alloy in a lot of things, from kitchen utensils to automobiles, even in our electronics. It’s incredibly useful, and it is extremely rare for you to find a welder that doesn’t know how to work with them. However, it’s certainly not without its flaws either. Even as an alloy, aluminum is one of the most malleable metals in the world. It is prone to bending or warping under certain conditions like improper distribution of weight, intense heat, or any powerful outside force. For aluminum fabrications in Leeton, this is quite troublesome because it could cause the welds in the joints to crack and, in the worst cases, break altogether. When this happens, what exactly can you do?

We have good news for you. Repairing damages on aluminum welds is much easier than most people think, given that you have the materials to do it. Although it certainly helps to have an experienced aluminum fabricator do it, any person with basic welding training can pull it off without any issues. In this article, we’ll explore the most common methods of repairing a cracked aluminum weld.

What you’ll need:

First of all, make sure you have all the proper safety equipment before you start welding. This includes gloves, protective goggles, and a welding helmet. A welding apron can also come in handy if you don’t want splatter ruining your getup.

Although it is possible to make repairs using a multitude of welding methods in Hillston, we’ll keep this guide simple and focus on TIG welding. It is arguably the best option for making repairs because you have better control over the application of the filler metal. It’s also great for making small, precise welds that you’ll often encounter when repairing small cracks. Prepare all the materials you normally would have when you’re doing TIG welding. We recommend using a serrated tungsten electrode and a 4043 aluminum filler rod. Set the TIG welder to AC at around 200–300 amps output, going for higher amperage as the thickness of the weld increases.

You will also need a drill and a grinder for when you have to smoothen out the crack before you weld. As for the steel brush, we recommend using one that is used specifically for aluminum, to avoid contaminating the joint as you clean it. Last but not least, you should have a clean welding rag and acetone.

Step 1: Prepare the weld

Identify the correct length of the crack by marking the areas where it starts and where it ends. You should also take note of its depth, especially if it extends to the base metal. Drill a hole at both ends of the crack, then grind out the crack so it becomes a V-shaped indentation or groove. Make sure you grind as deep as the root of the crack to prevent it from reappearing. Next, cleanse the area with a clean rag soaked in acetone, then scrub it with a steel brush, making sure to reach deep into the crack so the acetone can clean it as well.

Step 2: Welding the Crack

Begin welding where the crack starts, ideally in one of the holes you drilled earlier. Heat the base metal first before you add the filler metal. Start filling in the groove with the filler metal, following the usual steps in welding you’d normally do with TIG welding. Be careful when you apply the filler metal, because applying it when the base metal has not yet been properly penetrated might cause the filler metal to accumulate at the top instead of merging with the base metal. Slowly make your way to the other end of the crack. Leave no gaps in the groove, as these may turn into new cracks in the future.

Step 3: Finishing Up

Get your wire brush once more and clean the weld area. When done correctly, you should see an even row of beads where the crack had once been. 

Conclusion

That should be enough to ease your worries the next time you see cracks in your aluminum fabrications. Note that when you’re working with other materials, like stainless steel fabrication, the process might be slightly different, but the core concepts remain. If you’re not too confident with your TIG welding skills yet, practice on a small plate of aluminum first. Work on applying the filler metal evenly to get the right amount consistently. There are several references online you can look at to tell if your weld was done correctly, but don’t sweat it if you don’t get it the first time. 

Looking for professional metal repair, modification, and welding services in New South Wales, Australia? Give Topweld General Engineering a call today, and we’ll set you up with our finest welders right away.

Learn more about aluminum fabrication using this guide: ALUMINUM FABRICATION: BASIC GUIDE 2023

People use aluminum, a versatile metal abundant in nature, in a variety of applications, such as utensils, power tools, electronics, and vehicles due to its unique properties. However, welding requires much more finesse because it is a considerably softer and more delicate metal. Topweld, a major provider of welding services in New South Wales, often gets asked why fabricating aluminum projects is different from other metals. To educate our customers and aspiring welders, we’ve prepared an article that explains how to weld aluminum, the methods used, and how we ensure they look good. We love to post articles that discuss how we typically conduct our professional metal fabrication services in Wagga Wagga, NSW. If you are curious about what steps in welding are involved whenever we take on a certain project, consider browsing our other blogs on this website.

“Knowing what you’re working with” is “working with”

Amateur welders often mistakenly think that they can weld every metal in the same way. However, aluminum is a unique metal that requires a specific welding process due to its soft, malleable, and corrosion-resistant properties. Aluminum is often used in kitchen utensils and canned food packaging because of its non-toxic properties, but it is not very strong in its pure form, so most fabrications use alloys.

Preparations

To start welding, you need various tools and materials, some of which depend on the welding method you’ll use. A welding helmet is essential to protect your skin from the sparks and hot particles produced during the welding process.

It also reduces the intensity of the light that reaches your eyes while you work. Gloves are also handy (literally) for the same purpose as a helmet.

Thicker gloves can reduce your control over the weld. This is crucial to keep in mind as we discuss TIG welding in Young, NSW. You may also need a hammer, brush, and clamp to weld the base metals together.

Finally, a metal file and a grinder are useful for polishing the weld once you finish welding the pieces together.

“Welding Process.”

As mentioned before, Aluminum is a delicate metal, even as an alloy. Using the wrong welding method can disfigure the base metals and affect the appearance of the final product.ugly and crooked. It could also produce excess soot that can be difficult to completely clean off. If you want to get the best possible weld for this material, you should look at either MIG or TIG welding. Here’s the difference between the two.

• MIG Welding – uses a machine that continuously feeds a wire into a spool gun. The wire functions as both the electrode and filler metal, while the spool gun shields the pool with gas. It is a fast and easy method for welding aluminum and other metals, but requires maintaining a steady arc by adjusting the wire feed speed and voltage.The goal is a consistent transfer of filler metal onto the pool without excessive spool gun oscillation.

• TIG Welding – TIG welding is more challenging than MIG welding as it requires precision, coordination, and patience. It uses a non-consumable tungsten electrode and the welder manually feeds the filler metal into the weld pool. However, this allows for greater control and is suitable for thin aluminum and other metals like stainless steel and titanium. Experienced welders are recommended to master TIG welding for producing a finer weld. If someone is in a hurry or has limited resources, they should seek professional assistance.

PRO TIP: Make sure to brush off the layer of oxide on the base meals using a brass brush or sandpaper specifically used for metal before you start welding. Furthermore, keep the surface of both the base and filler metals clean and dry by wiping away oil and grease. Taking these steps will prevent contamination of the weld.

“To Sum It All Up” is “Sum It All Up.”

Welding is an intricate process, even more so when handling materials like aluminum. In this article, we aim to teach you about our welding services and how you can do it yourself. Thanks to advancements in technology, the cost barrier for welding is now lower, but if you need an expert hand, Topweld is here to help. Give us a call today and we’ll offer a helping hand.