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aluminum welding and fabrication

What is needed for aluminum welding?

Tungsten inert gas (TIG) welding is the primary method used to weld aluminum. Because the aluminum work piece requires a lot of heat to get up to temperature–but can hold that heat for a long time–a welding machine with current control is useful for keeping the aluminum work piece from overheating, causing a burnthrough. TIG welding can be applied to both thin aluminum sheeting and thicker aluminum plate. Because TIG welding requires a separate filler rod, the welder must choose a welding rod with an alloy as close to that of the work pieces as possible.

Alsom here is another way you can weld aluminum

Metal inert gas (MIG) welding can be successfully used to weld aluminum. … When choosing a shielding gas, 100 percent argon is best for MIG welding aluminum. The welder must choose a welding wire or rod that has an alloy as similar to that of the work pieces as possible to create a quality weld

Howe hot to weld aluminum depends on the  of the metal below im listing something  that can help

In general, GTAW power sources with an AC/DC output come in four categories, which are listed here in order of lowest to highest price:

1. Light fabrication. Machines designed for light fabrication usually have an AC output from 20 to 165 amps. While they do not incorporate a square wave output or balance control technology, they do produce an arc suitable for a variety of work, including applications for the home hobbyist.

2. Light industrial, maintenance/repair, metal fabrication. This newer class of light industrial machine provides roughly a 15 to 180 AC output and a professional-quality arc. Key features include: a square wave output, a fixed balance control set for more penetration than cleaning (a 60/40 electrode negative (EN) to electrode positive (EP) ratio works best for most applications), built-in high-frequency starting for positive starts without arc wandering, and a built-in stabilizer for a more consistent arc while welding.

3. Industrial production, fabrication, aerospace, repair. Industrial production GTAW power sources have a square wave output with an adjustable balance control. Greater amounts of EN create a deeper, narrower weld bead and better joint penetration. Greater EP values remove more oxide and create a shallower, wider bead. Transformer-rectifier GTAW machines can adjust EN values from 45 to 68 percent.

Machines are available with a variety of outputs, typically rated at 250, 350, and 500 amps with a 40 or 60 percent duty cycle. The low-end amperage range listed for these machines is usually 5, 3 or 25 amps, respectively. These power sources have created millions of code-quality GTA welds.

4. Inverter-based AC GTAW machines. Also considered industrial power sources, an inverter gives the professional welder more capability to tailor the width, depth and appearance of the weld bead for an application.

Inverters can adjust EN duration from 50 to 90 percent. Adding more EN to the cycle may: increase travel speed by up to 20 percent, narrow the weld bead, achieve greater penetration, permit using a smaller-diameter tungsten (to more precisely direct the heat or to make a narrower weld bead), and reduce the size of the etched zone for improved cosmetics.

Operators can adjust the welding output frequency in the range of 20 to 250 hertz. Increasing frequency produces a tight, focused arc cone. This narrows the weld bead, which helps when welding in corners, on root passes, and fillet welds; it also permits faster travel speed on some joints. Decreasing output frequency produces a broader arc cone, which widens the weld bead profile and provides greater cleaning action.

GTAW inverters accept single- or three-phase, 50- or 60-hertz, 230- or 460-volt input power. This provides flexibility when moving the machine between jobs sites or around a large facility. Using three-phase power and welding at 300 amps (460 volts primary), an AC/DC GTAW inverter requires only 18 amps of primary current. A 5- to 300-amp AC/DC GTAW machine weighs about 90 pounds

Friction stir aluminum welding

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Close-up view of a friction stir weld tack tool.

The bulkhead and nosecone of the Orion spacecraft are joined using friction stir welding.

Joint designs

Friction stir welding (FSW) is a solid-state joining process that uses a non-consumable tool to join two facing workpieces without melting the workpiece material.[1][2] Heat is generated by friction between the rotating tool and the workpiece material, which leads to a softened region near the FSW tool. While the tool is traversed along the joint line, it mechanically intermixes the two pieces of metal, and forges the hot and softened metal by the mechanical pressure, which is applied by the tool, much like joining clay, or dough.[2] It was primarily used on wrought or extruded aluminium and particularly for structures which need very high weld strength. FSW is capable of joining aluminium alloys, copper alloys, titanium alloys, mild steel, stainless steel and magnesium alloys. More recently, it was successfully used in welding of polymers.[3] In addition, joining of dissimilar metals such as aluminium to magnesium alloys has been recently achieved by FSW.[4] Application of FSW can be found in modern shipbuilding, trains, and aerospace applications.[5][6][7][8][9][10]

It was invented and experimentally proven at The Welding Institute (TWI) in the UK in December 1991. TWI held patents on the process, the

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