But my friend, I was just making you aware of the problems that most people face and end up rendering the weld useless. I might sound like a person who is too afraid to weld, much less handle aluminum. So, chances are the wire feed/deliver system will not work properly owing to incorrect machine settings, wrong technique, lack of maintenance, or low-quality wire. MIG welding requires the continuous feeding of a wire electrode through a spool gun. There is one more side to this particular job. Furthermore, excessive shrinkage during the solidification and cooling of the weld often results in stress cracking. Its chemical composition may lead to hot cracking. Thermal conductivity (approximately four times higher)Īll these make aluminum unusually susceptible to warping.Melting point (approximately 50% lower). With aluminum, the job only gets trickier due to certain properties of the metal at higher/lower levels than those of steel. Whether you weld aluminum or steel, you should be prepared to deal with some defects such as burn-through, craters, poor fusion, and porosity. Don’t make it commercial for it’ll be next to impossible to meet the welding code requirements.īefore telling you how to reduce porosity, I should let you be familiar with the difficulties which may hinder your efforts. You can remove much of the porosity if not all, and the project should only be intended for personal objectives, I mean DIY purposes. So, it seems you cannot really MIG weld aluminum absent shielding gases. More importantly, the amount of porosity will be too significant to ignore. The chemicals used to produce those fluxes are not ideal from an environmental consideration. None of those products can be what we call “perfect”. Its hygroscopic substance absorbs or attracts water from the surrounding air.ĭespite these limitations, you’ll see a small number of fluxes advertised as “effective for welding aluminum”.
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