The choice between 4043 and 5356 welding rods will depend on the specific application and the desired outcome.

4043 is commonly used for welding aluminum alloys with a high silicon content, while 5356 is often used for welding marine-grade aluminum. 4047 can also be used for aluminum with a low silicon content.

E4043 Welding Rod

• Aluminum with High Silicon Content (6xxx series)
• Used in automotive, shipbuilding, and general fabrication

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E5356 Welding Rod

• Marine Grade Aluminum (5xxx series)
• Used where aluminum will be exposed to salt water or other harsh environments

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E4047 Welding Rod

• Aluminum with Low Silicon Content
• Used in applications where high strength is required

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Can You Weld Aluminum?

Yes, aluminum can be TIG welded using a specific welding rod and process. However, welding aluminum requires special techniques and equipment to prevent cracking and ensure proper weld quality. It is also essential to clean and prepare the aluminum surface before welding to prevent contamination.

E4043

The numbers in a welding rod, such as 4043, represent the filler metal classification system. The filler metal classification system provides information about the composition and properties of the welding rod.

In the case of 4043 welding rod, the first two digits (40) indicate the minimum aluminum content of the welding rod, which is 40%. The last two digits (43) indicate the specific composition of the welding rod, which includes elements such as aluminum, silicon, and magnesium.

This classification system is commonly used for welding aluminum and other materials, and is governed by international standards such as AWS (American Welding Society) and ISO (International Organization for Standardization).

• Tensile Strength: 250-400 MPa
• Melting Point: 1065 – 1175°F
• Conductivity: 42% IACS (-O)
• Density: .097 lbs/cu.in
• Primary Alloying Materials: Silicon

This filler rod is not be suitable for welding aluminum alloys with high magnesium content.

E5356

E5356 filler rod has good corrosion resistance, which is important for preventing rust and other forms of corrosion in marine environments, where exposure to salt water and other corrosive substances is common.

I suggest using 80-150 volts, depending on the diameter of the rod.

• Tensile Strength: 340-480 MPa
• Melting Point: 1060 – 1175°F
• Conductivity: 29% IACS (-O)
• Density: .096 lbs/cu.in
• Primary Alloying Materials: Magnesium, Manganese, Chromium, Titanium

E5356 filler rod is well-suited for marine aluminum because of its low melting point, good corrosion resistance, adequate strength, and good welding characteristics, which make it well-suited for use in a challenging marine environment.

This filler rod is not be suitable for welding aluminum alloys with high silicon content.

Welding Rod Characteristics to Consider

The following are some of the characteristics of a welding rod that impact its ability to weld aluminum:

Composition:

The composition of the welding rod, including its elements and proportions, affects its ability to weld aluminum. Aluminum welding rods typically contain aluminum alloy and are designed to have low melting points, good welding characteristics, and adequate strength.

Some filler rods contain high amounts of magnesium or silicon, which can improve the strength and hardness of the weld.

The composition of a filler rod can also affect the appearance of the weld. Some filler rods contain alloys designed to improve the color and finish of the weld, which is important for applications where the appearance of the weld is a critical factor.

Melting Point:

The melting point of the welding rod is important because it affects the ability of the rod to flow and bond with the aluminum being welded. Welding rods with low melting points are typically better suited for welding aluminum, as they are less likely to crack or cause other issues during the welding process.

Typically, welding rods with melting points between 1100-1300°F are suitable for welding aluminum

The melting point of a filler rod can impact its ability to weld aluminum in several ways:

1. Weld Pool Formation: If the melting point of the filler rod is too low, it can result in a weld pool that is too fluid, making it difficult to control and resulting in a weak or porous weld. If the melting point is too high, the filler rod may not melt and mix with the base metal, resulting in an incomplete weld.
2. Weld Pool Stability: If the filler rod has a high melting point, it can help to maintain a stable weld pool and prevent the filler rod from burning away or boiling.
3. Weld Quality: A filler rod with a lower melting point may result in a weld with a lower tensile strength or a lower corrosion resistance, while a filler rod with a higher melting point may result in a harder and more brittle weld.
4. Weld Cooling Time: The melting point of a filler rod can also affect the cooling time of the weld, which can impact the properties of the weld and the final finished product.

Strength:

The strength of the welding rod is also an important factor in its ability to weld aluminum, as a weak rod may not provide adequate support for the welded joint.

A filler rod with high strength is important for applications where the welded joint will be subject to high stress levels, such as in structural applications or in the construction of heavy equipment. In these cases, a filler rod with a low strength may not be able to withstand the stress and pressure of the application, which can result in a weak or brittle weld that is prone to failure.

In contrast, for applications where the strength of the weld is not a critical factor, a filler rod with lower strength may be sufficient. For example, in artistic or decorative applications, a filler rod with a lower strength may be suitable as long as it provides a smooth and attractive finish.

Diameter:

The diameter of the welding rod affects the size of the weld and the amount of filler material required. A larger rod will generally produce a larger weld, while a smaller rod may be more maneuverable in tight spaces.

Corrosion Resistance:

The corrosion resistance of the welding rod is important if the aluminum being welded will be exposed to corrosive environments, such as salt water. This is generally dictated by the composition.

How Do You Clean Aluminum Before Welding?

Cleaning aluminum before welding is important to ensure a strong and quality weld. The following steps can be taken before welding:

1. Remove any dirt, oil, or grease from the surface of the aluminum using a degreaser and a clean cloth.
2. Use a sandpaper or grinder to remove any oxidation or corrosion from the surface.
3. Clean the aluminium surface with a solution of equal parts water and vinegar, or with a specialized aluminum cleaner.
4. Rinse the surface thoroughly with water to remove any residue from the cleaning solution.
5. Dry the surface with a clean cloth or allow it to air dry completely before welding.

It is important to avoid using any steel brushes or other tools that can leave behind metal contaminants, as these can weaken the weld. It is also important to avoid touching the aluminum with bare hands, as oils and salts from the skin can also contaminate the aluminum.

Conclusion

Choosing the right filler rod for welding aluminum is essential for achieving a strong and durable weld. E4043 and E5356 are two popular filler rods for welding aluminum, each with unique characteristics and specifications. E4043 is a versatile filler rod well-suited for many aluminum welding applications. At the same time, E5356 is a filler rod that is particularly well-suited for marine aluminum due to its high magnesium content.

The specifications of these filler rods, including their melting point, chemical composition, tensile strength, and welding current, are important factors to consider when choosing the right filler rod for a specific application.

The post 3 Best Welding Rods for Aluminum appeared first on Beginner Welding Guide.

TIG welding is a type of welding that uses a fixed tungsten electrode to create the arc. While TIG welding is a bit harder for beginners than MIG welding, that doesn’t mean you can’t attempt this technique without tons of experience. Many beginners find TIG welding a pleasant experience once they get the hang of it.

Choosing the right welding machine is one important factor in learning how to TIG weld when you’re a beginner.

Keeping these factors in mind can seem overwhelming. That’s why we put together this guide to choosing a TIG welder for beginners that can help you.

Best Stick Welder

Amico 200 Amp Stick/TIG Welder

• Powerful Capable of Welding up to 3/8 inch Stainless Steel
• Almost Non-Existent Spatter and Post-Weld Cleanup
• Dual Voltage Input - 110V/230V
• 13 ft Torch Cable

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Best Value for Money

Everlast PowerTIG Welder

• AC/DC TIG Welder
• Can Weld Up to 1/2 Inch Steel
• 12 ft Torch
• Complicated User Interface

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Best Premium Option

Lincoln Electric 200 Amp TIG Welder

• Powerful 200 Amp TIG Welder
• Well Suited for Aluminum
• 115 or 230V Supply Voltage
• Premium TIG Welding Machine

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What Is TIG Welding?

Before we get into the nitty-gritty of choosing a TIG welding machine, let’s analyze what TIG welding is in the first place. TIG welding stands for Tungsten Inert Gas welding. During this welding process, the welding machine uses a fixed tungsten electrode to spark the arc, instead of a consumable electrode wire such as in MIG welding. The weld is shielded by an inert gas. 

TIG welding works by holding the electrode a short distance away from the base metal, sparking the arc. You turn on the inert gas to protect the area around the weld. Sometimes, you need to add a filler rod to create the weld pool since the electrode doesn’t melt to fill this space. 

TIG welding is a bit harder than MIG welding for a few reasons. TIG welding machines require extra coordination because you also have to hook up the inert shield gas. Plus, most TIG welding machines require you to use your hands and feet to operate them—a far cry from most MIG welding machines which you can operate in one hand. 

Why Choose TIG Welding?

If TIG welding is so much harder than MIG welding, you might wonder why people want to do it. Why not just stick to easy MIG welding?

TIG welding offers some advantages that other types of welding don’t have. One of the biggest ones is the quality of the weld. Once you master TIG welding techniques, you’ll see how much better the weld looks than one that you can produce with another type of welding machine. Not only will the joint look better, but it will be stronger and create less work for you because you don’t have to clean up afterwards.

TIG welding also offers a superior welding experience. You will have greater control over your machine as a welder when you use this method. Tungsten is stronger than other electrode materials, so you don’t have to worry about it melting or flopping out of position. You control the amperage of the machine every second with a foot pedal, while for other machines you can’t adjust the amperage in the moment.

Finally, TIG welding is a very versatile type of welding you can use in almost any situation. It does take some time to master this technique, but once you do, you’re set for any welding you want to do.

What to Look for in a TIG Welder

A few different factors can help you determine if the TIG welder you are looking at is right for you. These factors include:

• Duty cycle
• Portability
• Foot pedal capability
• Stick welding capability
• Air-cooled vs. water-cooled torch
• Arc stability

We’ll examine each of these factors in more detail.

Duty Cycle

The duty cycle of a welding machine determines how long it can run at a certain amperage without overheating. The label will express duty cycle as a percentage at a given amperage. The percentage tells how many minutes out of ten minutes the welding machine can be turned on. For example, a duty cycle of 60% means you can run the welding machine at the specified amperage for six minutes.

Many welders think getting a machine with a longer duty cycle is always better, but that is not the case. It really depends on what you will be using the machine for. For example, if you are planning delicate welding or certain repairs, you won’t need to use the machine for long periods anyway, so you can get one with a shorter duty cycle.

TIG welders generally don’t require very high duty cycles, compared to MIG or stick welding. Picking a TIG welder with a 30% duty cycle is likely sufficient for a home-based beginner welder.

Portability

TIG welding machines come in many different sizes. What size you get depends on the type of jobs you perform. Smaller TIG welders weigh about 40-50 pounds, making it easy to move them around your workshop, take them outside, or even take them to another location. You’ll need a more portable welder if you work outside a lot or do house calls for work.

However, what you gain in portability you lose in power. Smaller welding machines are less powerful, which is fine if you’re doing small repairs, but not if you’re welding thick metal. Get a larger welding machine of over 100 pounds for a professional workshop. It is harder to move, but more powerful.

Foot Pedal

One unique feature of TIG welding is that these machines have foot pedals that allow you to deliver consistent amperage. Sometimes, the foot pedal can replace one of your hands, especially if you are welding out of position.

A reliable foot pedal is one of the most important things to look for when shopping for a TIG welder. Make sure the pedal is responsive and at an angle that makes it easy to use, even during prolonged periods. While you can always add a top-notch foot pedal, it’s easier to get a welder with a quality pedal in the first place.

Stick Welding Capability

Part of the versatility of TIG welding machines is that you can use these welders to perform other types of welding, including stick welding. These welding machines have an extra attachment that can perform stick welding. Some TIG welding machines even include plasma cutting capabilities. You can cut and weld metal with the same machine. Those are some pretty powerful accessories!

Stick welding capability is a nice feature, but not always necessary. If you already have a stick welding machine, or know that this is a type of welding you aren’t going to do very often, it’s not worth splurging the extra money to get a TIG welder that can double as a stick welder. You can get a perfectly good TIG welder for a much lower price without looking for these extra features.

Air-Cooled vs. Water-Cooled Torch

Most TIG welders have air-cooled torches. Some high-end models boast water-cooled torches instead. This means the torch has a built-in cooling system that circulates water or coolant to keep the torch cool. 

If you often work at very high temperatures, a water-cooled torch will be much more comfortable and give you more control over the weld. However, a water-cooled torch might be a waste of money if you stick to medium temperatures.

Arc Stability

Last but certainly not least, you should look at the arc stability of your welding machine. You want your arc to be steady instead of fluctuating and spluttering as you use it. Unsteady arcs will affect the quality and appearance of your welds. 

Unstable arcs are a common problem with low-end models of TIG welders, so be sure to read reviews before you purchase a TIG welder. Spending extra money for more stability is worth it.

How to Start the Arc

There are three types of arc starting mechanisms for TIG welding machines. Deciding which one sounds better for you can help you narrow down the type of TIG welding machine you want to buy.

1. Scratch Start: To scratch start an arc, strike the arc against the metal like you would strike a match. Most modern inverted welding machines don’t use this start anymore, but older transformer models do.
2. Lift Start: Lift starts are some of the easiest arc starting methods. You touch the tungsten electrode to the metal and lift it off. A sensor tells the machine to start and it strikes the arc. This is only possible with modern inverted welders.
3. HF Start: For an HF start, you don’t need to touch the tungsten to the metal at all. Instead, you put the electrode near the job, and press a trigger to start the arc. Most professional machines have this start option. HF starts are great for jobs where you’re worried about tungsten contamination.

Once you know which start type you need, you can look for machines with this capability.

Final Thoughts

There is a wide range of TIG welding machines, differing in terms of quality, price, and extra features. A few features can help you determine which welding machine is right for you, but look for good arc stability and a foot pedal first.

The post How to Choose a TIG Welder for Beginners appeared first on Beginner Welding Guide.

Newcomers have many different techniques to master, including stick welding, MIG welding, and TIG welding. Most beginners stick to MIG or stick welding because it is easier to master if you are a newcomer, but TIG welding has its advantages. Learning TIG welding as a beginner welder is easy once you follow the right steps.

To learn TIG welding, you must first understand the differences between this type of welding and other types, such as MIG or stick welding. Then, figure out a TIG welding machine and start using it for smaller projects.

We’ve prepared more detailed instructions for learning TIG welding, so keep reading to learn more.

What Is TIG Welding?

Before you touch a TIG welding machine, you should understand this type of welding.

TIG welding, or Tungsten Inert Gas welding, is a type of welding that uses a tungsten non-consumable electrode to start the arc. The inert gas is a type of gas that creates a shield around the metal. 

TIG welding is popular in manufacturing, among professional welders, and even among some amateurs who appreciate the delicate properties of the welding process.

How Does TIG Welding Work?

TIG welding works in a similar way to other welding machines. The electrode creates an electric arc between the welding machine and the metal. The heat from this arc melts the metal, creating the weld pool. The inert gas creates a shield around the weld to prevent the molten metal from oxidizing.

However, TIG welding is a bit more complex than other types of welding. First, you strike the arc, usually by striking it against the surface like a match. Once you strike the arc, you use one hand to hold the arc close to the surface and move it along the joint. 

With the other hand, you feed in the filler metal rod. Since the TIG welder uses a nonconsumable electrode, you need to get the metal for the weld pool from somewhere else. Finally, you use a foot pedal to continuously control the length of the arc and how much power you supply to the welding machine.

TIG welding is a bit more complex than MIG welding or stick welding because you have to use both hands and a foot to operate the machine. You also have to coordinate the filler material yourself. It does take time to master this coordination, especially if you are a beginner, but once you do, you’ll be TIG welding in no time.

When to Choose TIG Welding

If TIG welding is so complex, you might be wondering why you need to learn it in the first place. The truth is that TIG welding is much better than other types of welding for certain applications. Here are some situations where TIG welding is the best choice:

• Welding thin metals, such as metals used in medical equipment
• Pipe welding
• Welding complex projects such as airplanes, automobiles, and spacecraft

What Metals Does TIG Welding Work On?

TIG welding works on almost every type of welding. However, there are certain metals for which TIG welding is the best choice. For example, TIG welding is the best choice for nonferrous metals, which are metals that don’t contain iron.

Here is a list of metals you can use TIG welding for:

• Steel
• Stainless steel
• Aluminum
• Bronze
• Copper
• Titanium
• Magnesium
• Nickel and its alloys
• Precious metals such as gold

How to Learn TIG Welding

TIG welding fills a gap in your workshop that other forms of welding, such as MIG and stick welding, cannot meet. You might be really excited to learn this new welding technique to fulfill your mastery of welding.

However, you shouldn’t learn TIG welding alone. Either take a workshop or class at a local technical school or apprentice with a master welder. 

There are a few reasons why you shouldn’t learn TIG welding from online tutorials and videos, which is how you might have mastered other welding techniques. TIG welding is much more complex than these other techniques. It requires a level of coordination you don’t have if all that you’ve done before is MIG or stick welding. Teaching yourself these coordinated movements is a lot harder than learning from a professional.

Another reason is safety. Since TIG welding is so much more complex than other types of welding, the chances that you will accidentally injure yourself are much higher. It’s safer to learn TIG welding in a supervised environment, where a professional can stop you if it looks like you are on the way to injuring yourself.

Finally, TIG welding setups are a lot more complex than MIG or stick welding setups. To get the welding machine working properly and follow codes for safe TIG welding use, you need to have certain conditions in your workshop. Kitting out a DIY home workshop to TIG weld properly is logistically difficult and expensive. Plus, it makes no sense to go to that effort if you don’t even know if you like TIG welding.

For all these reasons, if you’re interested in trying out TIG welding, it’s best to seek out a professional to teach you. Once you have a professional instruct you, it will be easier to turn TIG welding into a job if you wish.

How to TIG Weld

Here are the basic steps to TIG weld. Remember, if you’ve never done this before, learn from a professional first. Don’t just follow the steps laid out in this post.

1. Prepare Your Setup

Make sure that your TIG welding machine has the right electrode inserted. Grind the electrode to a point, as most electrodes come with a rounded tip when you first open them, and this is less precise. Insert the electrode into the collet, which is the holder for the electrode.

Once your electrode is set up, you can prepare the rest of your welding machine. Check the levels for the inert gas so that you have enough shield gas. Adjust the settings on your TIG welding machine so it is right for your project. You can choose the current type (AC, DCEP, or DCEN), amperage, and other settings.

Last but not least, make sure you have taken all the safety precautions you need before welding. Clear the surface of your welding table. Clamp the metals in place so they don’t move as you’re welding. Put on all your protective gear, including a helmet, gloves, boots, and long welding clothes.

2. Strike the Arc

Finally, you’re ready to weld. You can strike the arc by striking the electrode against the metal. If you can’t do this because you’re worried about contaminating the base metal with your electrode, most TIG welders have a button you can use to start the arc.

3. Create the Weld Pool

Focus the electrode on one part of the metal and add your filler rod. Melt the metal to create the weld pool. Pump your foot pedal to increase the amperage levels (you will decrease them later, this is just to get the pool started). Once the weld pool forms at an edge, move quickly. You don’t want to focus the heat for too long on one part of the metal.

At this step, you can do a quick tack weld to help hold your metals in place.

4. Weld along the Joint

Decrease the amperage you are putting in with your foot pedal slightly. Move the electrode along the joint while consistently feeding in the filler rod to create a consistent weld pool. This should create a steady bead.

You will either “lead” or “follow” the electrode. Leading is when the rod moves down the line, followed by the electrode. For “following,” the order is reversed. This order depends on the type of metal you are welding.

The type of weld you make will depend on the purpose of your weld as well as a few different factors. You can make strength, cosmetic, lap, and fillet welds, just to name a few. 

5. End the Weld

Once you reach the end of the joint, taper off the amperage of the machine. Add a bit of filler metal and keep the shield gas on for a few seconds to make sure oxidation doesn’t happen. Finally, you can turn off the machine and let the weld cool. Clean up later.

TIG Welding Projects for Beginners

Once you learn the basics of TIG welding, the best way to perfect those skills is with a few simple projects. Some good projects to start off with include:

• An aluminum tote tray
• Welding tools such as a bronze hammer
• A picture frame

Use simple techniques and small pieces to get the hang of TIG welding.

Final Thoughts

TIG welding is a useful welding technique to have because it is one of the best ways to weld thin and nonferrous metals. However, it is difficult to master for beginners, so we don’t recommend trying to teach yourself. Go to a course or complete an apprenticeship instead.

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Argon and helium can be used in pure form or a mixture. Hydrogen can’t be used alone because it will harm your metal, but it has some benefits when mixed with argon or helium. 

Before understanding why we use those particular gasses and sometimes mix them, you need to know briefly about the TIG welding process. 

TIG Welding: A Quick Overview

TIG welding utilizes a non-consumable electrode. The word (non-consumable) comes from that electrode’s extremely high melting point.

In other words, the resulting heat will melt and weld the base metal, not the electrode itself. 

For this process to start, there must be an electric circuit like a battery. The electrode is usually the negative pole while the metal you’re welding is the positive pole. 

The point of contact between both poles is where the welding process occurs. An (arc) is created at this point, producing the high temperature. The molten metal in the welding area may react with the water vapor and the oxygen in the atmosphere, resulting in undesirable impurities.

This is when shielding gases like argon, helium, and hydrogen come into play. Being inert, these gases will cover the welding area and prevent the molten metal from reacting with any air elements.

Now let’s understand the characteristics that made us use those particular gases.

TIG Welding With Argon

The most common technique is using 100% pure argon as a shielding gas. Argon is cheap and widely available which makes it highly popular.

Argon also has a lower ionization potential, resulting in better arc starts and consistency than other inert gasses. 

The arc starts when the electrode comes in contact or close to the base metal. Argon provides a smoother arc creation whether you use scratch start, lift start, or high-frequency start. 

Since argon is a heavy gas, you should only restrict it to flat horizontal surfaces. The gravity will help keep the argon gas in place, shielding the welding process. 

Pure argon often gets the job done without mixing with other gases. It’s a good choice for welding aluminum, mild and austenitic stainless steel, and magnesium.

TIG Welding With Helium

We use 100% percent pure helium when we require higher temperatures. Helium has a higher thermal conductivity than argon, so it produces higher heat outputs.

The higher temperature allows you to weld faster and more efficiently. The heat also penetrates deeper into the metal, ideal for welding thicker materials. 

However, helium has higher ionization potential, which results in inconsistent arc starts, especially if your welding machine only allows you to scratch start.

This is why 100% helium is usually restricted to automated TIG weldings. Using pure helium in manual welding will yield challenges in starting the arc and maintaining it.

Helium is also more expensive than argon and much lighter, making it more suitable for overhead welding as the gas will travel upwards.

However, if you’re using the flat welding position, you’ll have to use twice the amount of helium (due to its lightweight) to stabilise the shielding, resulting in even more cost. 

TIG Welding With Hydrogen

We don’t use 100% pure hydrogen in TIG welding unlike argon and helium. It’s highly combustible and causes stress on the base metal, eventually leading to hydrogen-induced cracking.

Instead, hydrogen is mixed with argon to increase the arc voltage, resulting in a higher temperature and depth-to-width ratio. This makes hydrogen a useful gas if you are welding single layers.

Mixing hydrogen and argon also provides surface oxide cleaning, making the mix highly desirable for welding austenitic stainless steel.

TIG Welding Gas Blends

Here are two of the most common TIG welding gas blends:

Argon and Helium

Argon and helium mixture is the most common during welding. The usual percentages are 75% helium and 25% argon. 

You may reduce the helium percentage to provide better arc start and stability but lose some temperature and penetration depths. 

On the other hand, increasing the helium percentage will provide a better and faster ability to weld thicker metals. 

Argon and Hydrogen

Hydrogen can be added to hydrogen by up to 5%. This allows for higher voltage, heat, and penetration which helps with thicker metals.

The mix also allows for better arc stabilization, resulting in increased welding speeds.

How to Choose the Right Gas for Your Job

Here’s a small list for better functional suitability:

1. When to Use Argon

Without repeating all the characteristics mentioned above, it’s safe to say that with enough time and persistence, argon will get the job done in 90% of the cases.

Whether it’s mild steel, stainless steel, or aluminum, argon is your jack of all trades.

2. When to Use Helium

If your material has a low gauge (high thickness), you might want to add helium up to 75%. Keep in mind that helium will reduce arc stability. So, unless you’re welding an exceptionally thick metal, you don’t need to amp up the percentage of argon to 75%

Additionally, the location of your metal-to-be-welded is detrimental. The more horizontally flat your metal surface is, the less desirable helium will be, and vice versa.

3. When to Use Hydrogen

Like helium, hydrogen isn’t necessary unless you need extra heat and penetration. However, welding stainless steel may be more desirable because it cleanses oxidation from the metal surface.

However, be careful not to increase the percentage in the mix above 5% to avoid surface cracking.

In Conclusion

Argon is the best and most common gas for manual and automated TIG welding processes. It’s reliable, cheap, readily available, and produces a stable arc. 

If you have an inclined surface or a thicker material, you may want to add some hydrogen or helium to the mix. This will provide you with better heat, penetration, and efficiency.

The post What Gas Do You Use for TIG Welding? appeared first on Beginner Welding Guide.

Welding on a car requires different skills than regular welding. Plus, you have to be careful not to disrupt the electronics involved in making your car run. Taking precautions such as grounding your equipment and following the right steps is important to welding on a car.

Before you start repairing your own chariot, read this detailed guide.

Can You Weld on a Car?

Yes, you can weld on a car. Welding is actually an integral part of car manufacturing. That is how the metal pieces are created, from the frame to the doors. Car welding is a very lucrative career, as many factories are looking for qualified welders. If you want to weld professionally, this is one niche to explore.

You can weld on a car even if you’re just a hobbyist welder. However, welding on a car is harder than welding a table together or another simple project. The pieces are more complicated. If you make a mistake, the consequences are a lot bigger (especially if you decided to “fix” the family car on your own without telling your spouse). Finally, you can cause a lot more damage to the electrical parts.

So, the answer to if you can weld on a car is yes, but you have to be careful. If you’re a beginner welder, it’s probably better to start off with some simpler projects first.

How to Protect Your Electronics When Welding on A Car

One of the biggest dangers when welding on a car is that you will damage your electronics. This applies to your radio and stereo system and to the all-important computers that make up an Engine Control Unit (ECU). Metal conducts electricity, so when you weld, the electricity flows into your car’s electronics and damages it.

Before you start welding, you need to take precautions so you don’t permanently fry your ECU. First, look at the battery and locate two red or black packs terminals. Take out the negative one with a screwdriver and replace it when you’re done.

Then, make that you ground the metal you are welding. That way, electricity will flow into the soil instead of through your car and into the very sensitive computer systems.

Legal Requirements for Welding on a Car

There is no law preventing you from welding on a car. However, laws of the road can prevent you from taking your creation into traffic. 

You have to be very careful when welding a car frame. The Federal Motor Carrier Safety Administration states that frames cannot sag, the flanges cannot be damaged, and nothing can be welded to the frame. Cut-and-shuts, or welding the frames from two damaged autos together, are also illegal in most places. 

When welding automobiles, make sure that the parts you have are legit because if you are caught welding off the Vehicle Identification Number (VIN) or using parts from a stolen car, you could get in big trouble.

These are just federal laws. States and municipalities have their own laws regarding welding cars, so double-check first. If you’re messing around for a hobby, you should be fine, but double-check before taking your creation on the road.

Types of Welding for a Car

There are many types of welding that you can use on a car, including:

1. Tungsten Inert Gas (TIG) Welding

This form of welding is great for advanced welders who are conducting very delicate repairs. It uses a fixed tungsten electrode and a filler metal to weld metals together.

2. Metal Inert Gas (MIG) Welding

MIG welding uses a disposable wire filler and a shield gas to weld. MIG welding is great for beginners because you only need one hand to operate the welding machine, so you can use the other hand to hold materials in place or make other repairs. MIG welding is extremely versatile in terms of materials, thickness, and job size, making it perfect for nearly any work, including auto-body work.

3. Plasma Arc Welding (PAW)

Plasma arc welding is another form of welding that uses a tungsten electrode, like TIG welding. The electrode forms a plasma arc between the welding gun and the base material. This is more common in commercial settings because DIY welders don’t have much access to plasma welding machines.

Equipment Required

To start working on your car, you need a lot of equipment. Here is what your workshop should have:

• A welding machine
• Electrodes or filler wire
• Angle grinder to smooth out welds
• Pneumatic saw to cut metal and line it up into place
• Locking clamps to hold materials in place
• Body hammers to even out the metal around your repair patch
• Sheet metal gauge to make sure you’re using the right MIG size for your patch
• Safety equipment such as a welding helmet and gloves

Tips and Tricks

Auto welding is complicated because there is so much room for error. If you don’t have much welding experience, practice on some scrap metal, making similar welds you will use on a car.

Make sure to set up your work area properly, including cutting patches in place, sizing the right gauge, grounding your equipment, and putting all your supplies within reach. Some preparation can save you a lot of stress once you turn on the welding machine.

Final Thoughts

Once you are confident with your welding skills, you can weld on a car and save yourself a trip to the body shop. However, be careful not to damage the electrical systems and follow legal requirements when working on the frame.

The post How to Weld on A Car for Beginners appeared first on Beginner Welding Guide.

Carbide welding is common in many industrial applications. Its handiness in being resistant to abrasion and superior toughness has grown popular amongst other metals.

Construction professionals extensively use Tungsten Carbide in mining as drilling and cutting tools. You can trust Tungsten Carbide equipment for certain penetration against cement and asphalts.

But if you’re a starting or a novice welder, let me introduce you to the Tungsten Carbide.

Is There a Difference Between Tungsten Carbide and Tungsten?

Yes, there is. Simply put, pure Tungsten is an individual element commonly used for TIG welding. Tungsten Carbide is a composite material containing carbon and one other hard metal—you guessed it—Tungsten. 

What sets Tungsten Carbide apart is its strength, being much tougher than Tungsten metal. It’s why carbines are used to make cutting equipment for industrial machines. 

Its impressive durability makes it a great material for withstanding high temperatures like furnaces.

Science aside, welders refer to Tungsten Carbide directly as “Carbide.” In technical terms, this naming is incorrect and should be “Tungsten Carbide” or “Titanium Carbide.”

Can You Weld Tungsten Carbide?

As previously mentioned, you have the green light to do so. Welding Tungsten Carbide also means welding Carbide to steel without the element “braze alloy.”

Keep in mind the materials you’re using when welding Carbide. Not all metals are compatible with this compound, such as metals that contain highly in Nickel or Aluminum. Doing so will damage your joined workpiece, further degrading its quality.

But you can weld Carbide using the following:

• Stainless steels
• Tool steels
• Cast iron

Watch out for conventional welding methods, as they may be difficult. 

Remember that Tungsten Carbide is extremely hard and has a higher melting point. As a result, it’s harder to melt and more difficult to weld. 

But hey, what’s worth the effort always involves a little challenge.

Another useful tip is to avoid welding over Carbide. We’d want to steer clear of causing weld cracks.

What Are Weld Cracks?

These are weld failures that can either be a defect or discontinuity. Depending on the size, weld cracks can be alarming. They could lead to potential accidents that demand the utmost repair.

Carbides can have weld cracks because of the following:

• Excessive or high levels of stress in one area
• Improper use of welding procedure
• Lack of filler material at the end of the weld
• Unstable weld design

If a situation demands where you need to weld over Carbide, I’ve learned that brazing using silver solder works better. It keeps the temperature low enough to avoid changing the Tungsten Carbide’s components and overheating the area.

You can consider the ways I’ve listed below to prevent weld cracks:

• Use low hydrogen electrodes
• Cool the base slowly after welding
• Pre-heat base material
• Decrease welding voltage
• Follow the proper welding procedure

Why Weld Tungsten Carbide

The primary purpose of welding is to bind two pieces of an element using a durable filler material. But why do we weld Tungsten Carbide instead of any other metal? First, let’s examine its characteristics.

Being a product of two elements, it displayed unique traits:

Strength

Unlike other metals, Tungsten Carbide is helpful in any harsh environment with high vibration and pressure. This means you will have sturdy and reliable equipment.

Having a range between 8.5 to 9 on Moh’s scale of hardness, this metal is significantly stronger than steel and other equally hard materials.

Using Carbide to bind and fuse workpieces increases the strength of your weld.

Resistant to Wearing

Known as an effective hardening agent, Tungsten Carbides provide convenient traction and wear-resistant coating.

Corrosion is slower to spread, prolonging the lifespan of equipment or workpiece when welded.

Recyclable 

One of the most remarkable characteristics of a Tungsten Carbide is its recyclability. You can refine the used metal scrap into a better element through melting.

With this, you can reduce your carbon footprint and save money by reusing Tungsten Carbide scrap!

How to Weld Tungsten Carbide

We weld Tungsten Carbide on the tips or points of tools and areas where corrosion occurs. Here are the two ways of welding Tungsten Carbide:

Fusion Welding

You can achieve this method by melting two metals of a similar composition together. The goal is to melt both metals while they are still solid. 

You may or may not need a filler material for this to attach a smaller piece to a larger one.

Resistance Welding

Also known as Electric Resistance Welding (ERW), it’s a method that relies on pressure and electricity to create a magnetic force.

A current of electricity shall pass through, heating the welding joints and melting metals that will eventually forge together.

Equipment Required

You’ll need four pieces of equipment:

• Tungsten Carbide material (like groover or saw tips)
• Steel workpiece (can be your circular saw)
• TIG and MIG welders
• Filler metals

Safety Precautions

Be aware of the hazards Tungsten Carbide poses to avoid accidents. Here are quick tips on how you can prevent it.

• Follow the manufacturer’s instructions carefully
• Create a stable weld design
• Avoid weld cracks by not welding Tungsten Carbide with nickel and aluminum 
• Ensure proper welder installation and plugging
• Wear protective gear such as a face shield to not breathe in the dust that can lead to serious health conditions.
• Weld in fire-safe areas

Conclusion

Welding Tungsten Carbide has come a long way in the industrial business. It’s a hard, strong, and reliable material that gets the job done.

For the first while, welding this type of metal may be difficult. This might be especially annoying when you constantly get those weld cracks.

But once you get acquainted with Carbide welding and its equipment, you’ll understand its stark superiority over other metals. You might even find yourself constantly stacking up your tools with Carbide materials.

The post Can You Weld Tungsten Carbide? A Guide for Beginners appeared first on Beginner Welding Guide.

TIG welding works just fine for cast aluminum with a few technical and safety tips to keep in mind.

When Can You Weld Cast Aluminum?

You can determine if an aluminum casting is weldable according to two key aspects. The first is the composition, and the second is the casting method. 

Alloying Elements

Aluminum castings alloys can be one of eight types:

• Pure aluminum 1XX alloys
• 2XX alloys (aluminum and copper)
• 3XX alloys (silicon, copper, magnesium, and aluminum)
• 4XX alloys (silicon and aluminum)
• 5XX alloys (aluminum and magnesium)
• 7XX alloys (zinc and aluminum)
• 8XX alloys (aluminum and tin)

Each alloy type has a different weldability level. You can easily weld the 1XX alloys with 1100 fillers. However, the 7XX and 2XX alloys have poor welding characteristics.

You can also weld 3XX with 4043 fillers. You can use the 5356 fillers for the 5XX alloys.

Casting Method

Another factor that determines the weldability of cast aluminum is how it’s made. There are four common methods for making cast aluminum: die casting, investment casting, green sand casting, and permanent mold casting.

Die aluminum castings are pretty difficult to weld. This is because when you die-cast aluminum, you pressure-inject it into a steel mold that cools with water. This makes the casting cool in an instant.

The quick cooling of the cast prevents gasses from escaping. These pockets of air can be difficult to deal with during welding.

You can readily weld the remaining three casting types—permanent mold casting, investment casting, and sand casting.

When you make aluminum castings with these methods, they cool slowly. That’s because these castings mold metal into a low thermal conductor. This allows the gasses to escape freely from the casting.

Why Weld Cast Aluminum?

Cast aluminum has versatile applications, from small appliances to car parts.

Knowing how to weld cast aluminum can come in handy for repair jobs that include jet pumps, bolt holes, boat motor parts, and more.

How to Weld Cast Aluminum

The prep phase for cast aluminum is just as important as the welding.

You’ll need to remove the grease and dirt with a solvent like acetone. Use a stainless steel wire brush to tackle the oxide layer. You can then rinse and dry before welding.

TIG and MIG welding are the most common ways to weld cast aluminum.

Let’s check their techniques and benefits below.

TIG Welding Cast Aluminum

TIG weld is great for aluminum castings.

It can automatically remove the oxide layer. You don’t need mechanical wire feeding. TIG can also protect cast aluminum from contamination.

Here are some tips to consider:

• Prepare a 3/32 2% lanthanated tungsten electrode.
• Set the AC frequency to 50hz.
• Set the AC balance to 65% electrode negative to get more penetration.
• Turn on the shielding gas (pure argon works best for cast aluminum).
• Do another cleaning pass and preheat 200°F if the cast aluminum is still contaminated. 
• Weld with a forward and backward movement (I recommend starting from the outer edges to build up more heat).
• Add the filler of your choice, depending on the alloy composition.

Best Stick Welder

Amico 200 Amp Stick/TIG Welder

• Powerful Capable of Welding up to 3/8 inch Stainless Steel
• Almost Non-Existent Spatter and Post-Weld Cleanup
• Dual Voltage Input - 110V/230V
• 13 ft Torch Cable

Check Latest Price on Amazon

Best Value for Money

Everlast PowerTIG Welder

• AC/DC TIG Welder
• Can Weld Up to 1/2 Inch Steel
• 12 ft Torch
• Complicated User Interface

Check Latest Price on Amazon

Best Premium Option

Lincoln Electric 200 Amp TIG Welder

• Powerful 200 Amp TIG Welder
• Well Suited for Aluminum
• 115 or 230V Supply Voltage
• Premium TIG Welding Machine

Check Latest Price on Amazon

MIG Welding Cast Aluminum

Welding with MIG is another option for cast aluminum, but it can be complicated for beginners.

MIG isn’t versatile enough for cast aluminum. The welder could act up if your wire-feeding speed is a bit low or high.

MIG welds still have an advantage since it works faster for thicker cast aluminum.

Here’s how to do it:

• Get your choice of wire (ER5356 can be hard enough to facilitate wire feeding). 
• Start the wire-feeding process.
• Set the MIG machine to DCEP.
• Set the voltage to 21-24V, too. 
• Use a 100% argon shielding gas.
• Use a contact tip a size larger than the thickness of the wire.
• Weld with a swift, forehand movement and don’t move in circles. The key here is maintaining a steady speed.

Best MIG Welder

Lincoln Electric 180 MIG Welder

• 180 Amps Can Weld 1/2" Thick Mild Steel
• Aluminum Ready Spool Gun
• 3 Year Warranty
• Extremely Reliable and Durable

Check Latest Price on Amazon

Best Value for Money

Hobart Handler 140 MIG Welder

• Can Weld Up to 1/4" Mild Steel
• 20% Duty Cycle at 90 Amps
• 115V Supply Only
• Includes 10 ft MIG Gun and 10 ft Work Cable with Clamp

Check Latest Price on Amazon

Best on a Budget

Forney Easy Weld MIG Welder

• Infinite Voltage and Wire Feed Speed Control
• Extremely Lightweight and Portable at 19 lb
• Can Weld up to 1/4" inch Mild Steel
• 30% Duty Cycle at 90 Amps

Check Latest Price on Amazon

Equipment

Here’s what you’ll need depending on your welding method.

I have written a guide to my favorite aluminum welding machines.

TIG Equipment

You need to use a pure argon shielding gas for cast aluminum. You can also mix the argon with up to 25% helium for thick metal pieces.

Keep the gas flow at around 17 cfh for every 1/2 inch of cast aluminum. You can turn up the flow to 20 cfh if the arc is unstable from the ambient airflow.

Get 4043 fillers since you’ll most likely use 3XX cast aluminum alloys. The filler’s thickness should be around 1/16 to 3/16 inches in diameter.

An AC TIG welder with a cleaning action should do the job.

MIG Equipment

You’ll also use pure argon shielding gas for the MIG welder, just like with TIG welding. 

Get a welding wire like 4043 or 5356 that works for most cast aluminum alloys. I recommend a 5356 aluminum MIG wire instead of a 4043 one to avoid possible wire-feeding problems.

You’ll need an oversized tip for cast aluminum. This is because the aluminum wire expands with heat. A normal tip may get stuck when the wire is hot.

Safety Precautions

Safety precautions are crucial when welding cast aluminum.

Here’s why:

Cast Aluminum Doesn’t Change Color When It’s Hot

It’s hard to tell the difference between hot and cold cast aluminum. So, always wear your PPE.

Cast Aluminum Fumes Are Hazardous

The fumes that come from welding cast aluminum can harm your lungs in the long term. Neglecting these fumes can eventually lead to aluminosis, an irreversible lung disease.

I recommend getting a fume extractor to protect your health.

Cast Aluminum Is Very Reflective

Cast aluminum has high reflective properties. This puts you at risk of UV-related injuries such as welder’s eye.

Wearing goggles can help reduce the risks.

Conclusion

The alloy elements and the casting method determine the weldability of cast aluminum.

You can weld 3XX and 1XX alloys. You can also weld cast aluminum that is made by sand casting, investment casting, or permanent mold casting. Die castings won’t weld easily.

I recommend TIG welding cast aluminum simply for its convenience.

The post How to Weld Cast Aluminum: Recommendations appeared first on Beginner Welding Guide.

Aluminum is one of the most common materials in manufacturing; however, it is not commonly used in welding, particularly for beginners. The unique properties of this metal, which are very light, malleable, and flexible, make it great for other applications that require flexibility but are not ideal for an application such as welding.

However, following these tips, you can weld aluminum under certain conditions. Many advanced welders like to use aluminum for certain projects. Or they appreciate the challenge of welding a metal that isn’t usually welded. 

Whatever reason you want to work with aluminum while you weld, here are some tips to make it work.

Can You Weld Aluminum?

Although welding aluminum is difficult, you can weld it.

One way to do so is by combining aluminum with another metal to form an alloy. Alloys help combine the best that different metals have to offer. An alloy will cover up the weaknesses of each of the metals, creating a stronger substance. For aluminum, alloys make the metal stronger and more heat-resistant, especially when combined with sturdier metals. We recommend researching if an aluminum alloy is right for your project instead of pure aluminum and sourcing that instead, as the welding process is much easier.

You can also weld pure aluminum if you know the techniques to get around the metal’s quirks. Part of knowing how to weld aluminum is knowing why this metal is so difficult to work with.

One important factor is the oxide coating. Most aluminum is insulated by aluminum oxide, which requires higher temperatures to weld through, temperatures that could burn the aluminum underneath.

Getting the temperature right is difficult when welding aluminum, not just because of the aluminum oxide. Aluminum has a very low melting point but also conducts thermal energy thoroughly and does not show when it is melting. It is very porous, meaning that it absorbs impurities during melting easily. 

All these factors mean that welding aluminum requires knowledge about the metal itself, insight into welding processes, and the ability to notice when something isn’t going right and adjust accordingly. If you want to try welding aluminum, ensure you have the experience to make it work.

Welding Processes Suitable for Aluminum

One of the most important things to decide when to try welding aluminum is the welding you want to use. 

A few criteria determine which type of welding works best with aluminum. The process should have as little mess as possible to prevent metal contamination. Something like stick welding can work in a pinch but is not the best choice because it is messy.

It helps if the welding process uses filler material, such as flux. Using these materials makes it easier to detect when aluminum reaches the right temperature for welding.

However, you need to choose your filler material carefully.

Choosing the right method is also important because high-fuss methods, for example, types of welding that require manually feeding a wire as you weld, adding extra stress to a process already fiddly due to the nature of aluminum.

These are the best types of welding for aluminum: 

• Gas Tungsten Arc Welding (TIG)
• Gas Metal Arc Welding (MIG)
• Beam Welding
• Resistance welding (only in special circumstances)

How to MIG Weld Aluminum

MIG welding is one of the most common types of welding, not just for aluminum but also for many different metals. This type of welding uses an electric wire, fed continuously into the welding machine, to form an arc between the electrode and base metal.

MIG welding is great for aluminum because it is fast and efficient, creating minimal opportunities for contamination.

Here are the basics for how to MIG weld aluminum.

Prepare your work area

Welding aluminum requires more preparation than most metals. Make sure that your metal and electrode are very clean. Prepare your shielding gas and make sure it is an extremely important gas, such as argon or helium.

Welding aluminum requires other equipment, such as heat sink and push-pull wire feed.

Start welding

When MIG welding aluminum, most people recommend starting the arc about an inch before the welding point. Moving along the joint, move in one direction—pushing, not pulling. Keep a steady forehand angle and use a string bead technique.

Finish the weld

To finish off a MIG weld on aluminum, narrow the melting pool by quickly reversing the weld, then ending the arc. You want to avoid pockmarks if possible.

Best MIG Welder

Lincoln Electric 180 MIG Welder

• 180 Amps Can Weld 1/2" Thick Mild Steel
• Aluminum Ready Spool Gun
• 3 Year Warranty
• Extremely Reliable and Durable

Check Latest Price on Amazon

Best Value for Money

Hobart Handler 140 MIG Welder

• Can Weld Up to 1/4" Mild Steel
• 20% Duty Cycle at 90 Amps
• 115V Supply Only
• Includes 10 ft MIG Gun and 10 ft Work Cable with Clamp

Check Latest Price on Amazon

Best on a Budget

Forney Easy Weld MIG Welder

• Infinite Voltage and Wire Feed Speed Control
• Extremely Lightweight and Portable at 19 lb
• Can Weld up to 1/4" inch Mild Steel
• 30% Duty Cycle at 90 Amps

Check Latest Price on Amazon

How to TIG Weld Aluminum

TIG welding is another technique commonly used with aluminum. This technique, gas tungsten arc welding, uses a tungsten electrode. This automatically makes your life easier than MIG welding since you don’t have to feed in wire to act as an electrode, but the tungsten remains an electrode throughout.

TIG welding has a few other advantages that make it ideal for aluminum. It uses an alternating current, which helps strip the aluminum oxide and clean the material. It is ideal for thinner, more delicate materials such as aluminum.

Here is how to use TIG welding with aluminum:

Prepare your equipment

Ensure you have everything in place to weld, such as your electrode, alternating current welding machine, and aluminum. Clean your pure tungsten rod and aluminum ahead of time.

Prepare the electrode

Your tungsten rod should protrude only a little past the edge of the nozzle. You will hold it close to the aluminum for best results while you weld.

Add the filler material

Instead of using a filler wire, add the filler material to a puddle on top of the aluminum. 

Begin welding

Ensure you have a constant supply of gas and argon flow to the torch to make welding regular throughout the process. Keep your machine at a steady angle and speed. 

Best Stick Welder

Amico 200 Amp Stick/TIG Welder

• Powerful Capable of Welding up to 3/8 inch Stainless Steel
• Almost Non-Existent Spatter and Post-Weld Cleanup
• Dual Voltage Input - 110V/230V
• 13 ft Torch Cable

Check Latest Price on Amazon

Best Value for Money

Everlast PowerTIG Welder

• AC/DC TIG Welder
• Can Weld Up to 1/2 Inch Steel
• 12 ft Torch
• Complicated User Interface

Check Latest Price on Amazon

Best Premium Option

Lincoln Electric 200 Amp TIG Welder

• Powerful 200 Amp TIG Welder
• Well Suited for Aluminum
• 115 or 230V Supply Voltage
• Premium TIG Welding Machine

Check Latest Price on Amazon

Welding Machine Settings for Aluminum

No matter what technique you wind up using for aluminum welding, make sure that the settings are adjusted properly.

Since aluminum is usually thinner, make sure you adjust the machine properly. Experts recommend adding one amp for every 0.001 inch of the metal thickness. Depending on the technique, you may need to switch the amperage type. For example, TIG welding works best with AC current for aluminum.

Your heat point will also be different for aluminum than other metals, such as steel. Ensure you use a lower heat, around 1,200 degrees or slightly higher. 

Equipment Required

Welding aluminum requires some extra equipment. There are the basics, such as your electrode, welding machine, and wires, but here are the other important components:

Shielding gas

Shielding gas is important when welding aluminum because it prevents oxidation. Make sure you are using an efficient gas such as argon or helium.

Cleaning materials

You want to thoroughly clean aluminum before welding it to prevent contamination since its porosity makes it more prone to this problem. Make sure you have plenty of cleaning materials on hand.

Filler material

Whether using a filler wire or flux pool, you need filler material to weld aluminum properly.

Spool or push-pull gun

If you are using MIG welding, which uses a consumable wire as an electrode, use a gun to feed the wire into the machine instead of manually to save yourself some effort during the process.

Heat sink

Using a heat sink as you weld aluminum distributes temperature evenly around the material. Aluminum has high thermal conductivity, so you want to prevent heat from congregating in one place, causing warping.

Tips and Tricks

To optimize your experience while welding aluminum, here are some tips.

First, clean your aluminum thoroughly before welding. Strong soap and solvents can remove any surface impurities. Aluminum is very porous, so it is prone to contamination during welding. You can prevent this by cleaning.

It also helps to remove the oxidation layer before welding. That makes it easier to get the right temperature for welding aluminum. Use a brush just for cleaning aluminum to scrape off the oxidation layer.

Try to use a straight bead welding technique whenever possible. Straight bead welding is when you push or pull the welding beam in one direction without side-to-side movements. Consistency helps you achieve a smooth finish.

Finally, be careful how you store aluminum. Store aluminum sheets vertically when possible. Keep aluminum in a place where it isn’t exposed to contaminants.

Final Thoughts

Aluminum is a fussy material that is harder to weld than other metals, such as steel, but it is still possible to do. Choosing the right welding technique goes a long way. MIG and TIG welding are the best, as they minimize contamination and warping. With lots of patience, specialty equipment, and some experience, you can also weld aluminum.

The post Tips for Welding Aluminum: MIG and TIG appeared first on Beginner Welding Guide.

TIG welding gives you precise and resilient gold welds without costing a lot. Yet, TIG welding is technique-sensitive, despite the advantages. 

TIG Welding Gold

You can weld gold with welding techniques like TIG, MIG, and laser. TIG welding is the most suited for gold. 

High Precision and Quality

TIG welding has maintained its reputation as one of the most precise techniques. The weld puddle control is easy to use, so you can get precise welding by controlling heat input.

Plus, you can weld tiny thin gold pieces with the help of micro-TIG welds.

Micro TIG welds work by reducing the current to 5-300 amps. This low current gives you more precise welds with minimal thermal damage. 

Welders like to use micro TIG to weld tiny spots (about 0.25 mm) on thin gold. 

No Spatter

Spatter—the molten metal that splashes during welding—doesn’t occur with TIG welds. This is because you don’t necessarily need fillers for TIG welding. 

Further, you put the fillers inside the welding puddle when you want them, which helps prevent spattering. 

Equipment Required

Before you try TIG welding for gold, you must set up the equipment first. 

Here’s what you’ll need:

TIG Welder Machine

Pulse functionality is the most important feature in TIG welders if you frequently weld thin gold material. 

TIG welder machines that have pulse functionality work in a way similar to micro TIG. The pulse function lets you control the amp output, which is great for precise welding. 

So, whether you want to weld thick or thin gold pieces, you can do both. 

Another feature I recommend is getting an inverter TIG machine that automatically changes AC to DC. 

Standard welders usually use high AC voltage (220 V), while most households use a voltage of 110 V. So, you’ll need to use a transformer with standard welders. 

So, save yourself from many headaches by getting an inverter TIG machine. The machine will help you save on power consumption too.

Best Stick Welder

Amico 200 Amp Stick/TIG Welder

• Powerful Capable of Welding up to 3/8 inch Stainless Steel
• Almost Non-Existent Spatter and Post-Weld Cleanup
• Dual Voltage Input - 110V/230V
• 13 ft Torch Cable

Check Latest Price on Amazon

Best Value for Money

Everlast PowerTIG Welder

• AC/DC TIG Welder
• Can Weld Up to 1/2 Inch Steel
• 12 ft Torch
• Complicated User Interface

Check Latest Price on Amazon

Best Premium Option

Lincoln Electric 200 Amp TIG Welder

• Powerful 200 Amp TIG Welder
• Well Suited for Aluminum
• 115 or 230V Supply Voltage
• Premium TIG Welding Machine

Check Latest Price on Amazon

Shielding Gas

Shielding gas protects the molten metal from getting damaged by preventing exposure to atmospheric gases. I recommend using pure argon as a shielding gas. 

Pure argon gives the most precise welds compared to pure helium or mixed argon/helium. This precision is exactly what you want when you weld gold.

Welding Torch

To choose the right welding torch, ask yourself the amp type you’ll use for welding. If it’s a thick gold piece, the amp should be high, and vice versa.

Get a micro-torch for the thin, delicate gold pieces and another normal-sized torch for the thicker ones.

Electrodes

Picking the right electrode size mainly depends on the amp setting you’ll use. 

I recommend getting a pure tungsten electrode with a diameter of 1.6 mm for low amp settings. Pick a standard-sized 2.4 mm electrode for thick gold metal welding as well.

Laser Welding Gold

Laser welders are another excellent option for welding gold. Their accuracy and precision are superior even to TIG welds.

There’s a catch, though: laser welds are very expensive.

How pricey, you’re wondering? I’m talking about $10,000 upfront. Add in the laser accessories and materials—about $3,600—and you’ll need to pay $13,600. 

So, laser welders aren’t a popular choice for welding gold.

Step-by-Step Guide To TIG Weld Gold

You might find TIG welding for gold difficult at first, but it’s worth it once you get the hang of it. 

Here are the general instructions you need to follow:

1. Insert a Tungsten electrode into the collet, but make the electrode’s tip pointy beforehand.
2. Set the settings according to the thickness of the gold. Remember, low amp settings for thin gold, and vice versa.
3. Turn on the shielding gas.
4. Clean the metal and prepare the welding table.
5. Wear your PPE.
6. Hold the electrode and weld the metal.
7. Finally, if you’re using fillers, draw a bead.

Mistakes to Avoid When TIG Welding Gold

TIG welding is an excellent choice for its precision and cleanliness, but mastering this method involves a steep learning curve if you’re a beginner. 

So, here are the common TIG welding mistakes to avoid: 

Not Cleaning Gold Before Welding

TIG welders rarely spatter, as I mentioned earlier. Yet, if you don’t thoroughly clean the gold metal from dirt and other contaminants, you’ll get lots of spatter.

Lack of Shielding Gas  

Before you get used to the TIG welder, you may forget to turn on the shielding gas or don’t add enough of it. These things will end up contaminating the gold. So, make sure to check the gas flow rate. 

Generally, a flow rate of 20 cubic feet per hour works well with gold and other metals. If you set the gas flow higher than that, you’ll have an unstable arc and poor weld precision. 

Craters

Weld craters are thin, almost-cracked sections when molten metal isn’t enough to fill a cavity. 

You get weld craters when you suddenly reduce the current and cool down the weld too quickly. Slowly reduce the welding power to avoid this issue. 

Wrapping Up

If you were wondering, “Can you weld gold?” The answer is yes! TIG welding gold will give you precise and spatter-free pieces. 

All you need to get started is a TIG welder, a micro-torch, shielding gas, and electrodes. Just follow the safety precautions discussed above to ensure a safe and successful welding job.

The post Everything You Need to Know About Welding Gold appeared first on Beginner Welding Guide.

The early variations of the Heliarc welding process began around 1890 by  C. L. Coffin. It was originally called “electrode welding” and used a carbon arc to produce heat. The process wasn’t perfected until 1941 when it becomes more known under the name “Heliarc welding.”

You’ll learn everything there is to know about the Heliarc or TIG welding processes. We’ll go over the method, equipment, pros and cons, career options, and the most typical problems that could affect you.

What is Heliarc Welding?

The Heliarc Welding technique involves using tungsten electrodes and an inert gas. The machine uses a high-frequency current to heat the metal until it is transformed into a liquid form that can be joined together. You use electrodes to sustain the electric arc that is created between the materials.

The process is similar to gas welding, involving the melting of metal at the joint where two pieces meet. The difference with Heliarc welding is that this process does not use a filler material, unlike gas welding which uses carbon rods or electrode wire as it’s the source for the material.

What Equipment is used when Heliarc Welding?

The equipment involved in this type of welding includes a power supply that provides the electrical current needed to form the arc. You’ll need a few other items to complete the welding process, including a tungsten electrode, shield gas, and filler rods.

The most important piece of equipment is the torch. Some use non-consumable tungsten electrodes as well as those who typically work with consumable electrodes which wear down as they run through the machine.

There are several types of the weld from this technique including fillet, butt, and lap joints. The size of the workpiece is limited by the machine’s ability to produce enough heat.

What is Heliarc Welding Used For?

You’ll often find Heliarc or TIG welding used in industrial environments for larger-scale projects such as cars or ships. You can also use it for repairs on a car or home, but with most jobs, it requires a specialized machine with a lot of power, making it harder to do at home without proper equipment.

Tungsten Inert Gas (TIG) welding creates an affective bond between metals that strengthens them and eliminates impurities throughout the process. It is more complicated and harder to learn than other forms of welding such as MIG because it requires more precision and dexterity even though you are using gas to shield the products from exposure to oxygen.

Pros of Heliarc Welding

Let’s explain the positive side of Heliarc welding first.

Strong Welds

Using TIG methods allows products to be made stronger than they would by other forms of welding because it produces a strong metal bond. It requires less energy overall, making it more efficient overall.

Versatility

A benefit of Heliarc / TIG Welding is its ability to be used on materials including exotic metals, stainless steel, chrome, magnesium, aluminum, titanium alloys, and nickel alloys.

Quality Work

The process of TIG welding in this manner is accurate and can be completed with a high degree of precision, enabling it to be used to make critical parts and structures stronger.

Cons of Heliarc Welding

Two main cons of Heliarc welding are:

It Takes Longer to Learn

Heliarc welding involves a high degree of skill and dexterity, making it difficult to learn compared to other types of processes. It requires a strong understanding of electricity, angles, and time.

Without proper training, you might end up with an uneven joint or make mistakes in your alignment which could affect the strength of your product.

Multitasking

Since you need to maintain the arc, you can’t focus on one thing at a time. You’ll need to watch your gears and also know your timings before switching from one position to another.

Common Problems using a TIG welder?

When it comes to TIG welding, process, which is quite difficult to learn, things can go wrong easily. If you are not aware of the process, you might end up with a faulty final product or can get injured due to electrical shock.

Some common mistakes while using TIG welder includes:

Using too much or too less filler metal

When using filler metal during the welding process, it is important to use the correct amount in order to produce a quality weld. If too much or too little filler metal is used, it can affect the strength and appearance of the weld.

If too much filler metal is used, it can cause the weld to be bulky and uneven. This can lead to weak spots in the weld, leading to failure later. Additionally, using too much filler metal can slow down the welding process and make it more difficult to maneuver around the workpiece.

If too little filler metal is used, the weld will not be as strong as it could be. Additionally, it may not be able to hold up against wear and tear, which can lead to failure later on.

Incorrect polarity

Sometimes, the poles on a TIG welder can be put in the wrong spot. This means that the electricity will flow in the wrong way and it won’t weld very well. You might end up with a bad weld or even an injury if you’re not careful.

In most cases, DCEN or direct current electrode negative is used, but when welding aluminum or magnesium, AC or alternating current electrode positive should be used.

TIP: Read my post about Welding amperage selection

Improper Pulsing

The timing of the pulsing in a TIG welder is important. This is because it can cause problems with both the arc and the filler metal. For example, if the pulsing is too fast you might end up with porosity. If it’s too slow, you might end up cracking.

Using an incorrect gas or shielding gas

It’s important that you use the correct type of gas as it can affect your weld as well as its strength. For example, if you use a gas that is too rich, you could end up with a weld that may have excessive spatter.

If the gas is too lean, it can cause porosity to form in your final product.

Incorrect travel speed

Some TIG welders allow you to set a specific travel speed for welding so that you can ensure quality and speed.

However, if you go too fast or too slow with your travel speed, it could affect the accuracy of your weld as well as its overall strength.

At times an incorrect travel speed leads to bad puddle control and erratic arc behavior which leads to porosity in the final product.

Using a worn tungsten electrode

Using a worn electrode can cause problems when trying to create quality welds, which is another common mistake in TIG welding. A worn tungsten electrode will have a large ball on the end, which can cause an erratic arc and won’t transfer heat well so you’ll get cooling at the tip of your weld. This will give you poor penetration.

If your tungsten electrode is leaning to one side, you could end up with a concave weld puddle.

Heliarc Welding Career Opportunities

There are a number of career opportunities that involve the Heliarc welding process as well as those who have mastered it. For others, the reason for learning the skill is to perform welding on their own projects, whether it’s a car or something else.

Many jobs require Heliarc welding skills, including but not limited to:

• Industrial repair companies
• Machine shops
• Shipyards
• Racing car fabrication
• Scaffolders
• Heavy equipment operators
• Pipeline welding companies

Related Questions

Read Next

• How do I choose TIG welding cup size?
• MIG vs TIG Welding
• Are auto-darkening welding helmets safe?
• Best Welding Machine for Beginners
• What boots to wear when welding?
• Best Welding Helmets for the Beginners
• What is a plug weld?
• What is Tack Welding

The post Heliarc Welding: Unlocking the Pros & Cons appeared first on Beginner Welding Guide.

For TIG welding, common choices include #4 (1/4″), #5 (5/16″), #6 (3/8″), #7 (1/16″) and #8 (1/2″). To choose the best cup size for a particular welding project there are few tips, we are going to share with you.

Here are my recommendations for individual tig cups:

#4 Riverweld 1/4-inch TIG Welding Cup

• Pack of 10
• Fits all 9 series air cooled torches
• Fits all 20 series water cooled torches

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#5 Riverweld 5/16-inch TIG Welding Cup

• Pack of 10
• Fits all 9 series air cooled torches
• Fits all 20 series water cooled torches

Check Latest Price on Amazon

#6 Riverweld 3/8-inch TIG Welding Cup

• Pack of 10
• Fits all 9 series air cooled torches
• Fits all 20 series water cooled torches

Check Latest Price on Amazon

#7 Riverweld 7/16-inch TIG Welding Cup

• Pack of 10
• Fits all 9 series air cooled torches
• Fits all 20 series water cooled torches

Check Latest Price on Amazon

#8 Riverweld 1/2-inch TIG Welding Cup

• Pack of 10
• Fits all 9 series air cooled torches
• Fits all 20 series water cooled torches

Check Latest Price on Amazon

What is TIG Cup Size?

TIG cup size is a term used to describe the diameter of a TIG welding gas cup. Gas cups come in various sizes ranging from 1/4″ to 1/2″.

Size is important as it determines the shielding gas coverage you will have around the weld area.

Different sized cups have their pros and cons. The larger the cup, the more gas is available and the harder it is to move around. The smaller the cup, the more mobile it will be and easier it to maneuver in tight spaces.

Which TIG welding cup should I choose?

This set of welding cups made by YESWELDER is an affordable way to get a variety of cups in a single pack to get you started:

• 71 pieces TIG Torch Accessories (consumables)
• Excellent plasticity, toughness and crack resistance

Check Price on Amazon

There are a few things you need to consider when choosing a TIG welding cup size:

• What type of material are you welding?
• What is the thickness of the material?
• How big is the weld area?
• Can you get close to the weld joint?

What type of material are you welding?

Different materials will require a different size TIG cup. Titanium and in most cases stainless steel alloys need a larger cup due to the oxygen reacting with the base metal and creating a slag that floats on top of the molten puddle.

Carbon Steel on the other hand won’t be harmed by little oxidation so you can use the small gas cup during TIG welding.

What is the thickness of the material?

Thicker materials require a larger TIG cup size to allow more gas into the weld joint. Thinner materials can be TIG welded with smaller cups to get into tighter spaces.

How big is the weld area?

The size of the weld area will determine how big of a cup you need. A large weld area will require a larger cup size as more gas will fill the puddle. A small weld area can use a smaller TIG cup size as less gas is needed to weld the joint.

Can you get close to the weld joint?

If you are unable to get close to the weld joint, you will need a small TIG cup size to get inside of tight spaces and around the corners. A large TIG cup size will be required to get the proper shielding gas coverage if you can get close to the weld joint.

TIG Cup Size Chart

Air-Cooled vs Water-Cooled TIG Welding Torches

An air-cooled torch is great if you don’t have water available to cool the torch. In addition, they cost a lot less. The drawback of using them is bead length. They can not perform long enough before overheating.

When control or power is important and needed, use a water-cooled TIG welding torch instead. You will be able to weld larger bead lengths and thicker materials.

Water-cooled torches use a water jacket around the torch body connected to a water supply. The water jacket helps to cool the torch and prevents the TIG welding rod from sticking to the tungsten electrode. This is caused by the arc being hotter than normal. It protects the tungsten electrode from getting burned or broken off.

Water-cooled torches are more expensive than air-cooled ones, but the benefits make it worth the extra money.

Which type of TIG welding torch should I choose?

If you are using the TIG welder for your hobby or to build a custom chopper, you may want to consider using an air-cooled torch. If the TIG welder is for commercial use and welding thicker metals such as steel plates then a water-cooled torch should be considered.

Related Questions

Read Next

• MIG vs TIG Welding
• Do I need a TIG welder?
• Selecting Welding Amperage
• Best Welding Machine a beginner welder
• Which is the Best Welding Boot?
• Welding Helmets I recommend
• What is Heliarc Welding?

The post How Do I Choose a TIG Welding Cup Size? [Chart] appeared first on Beginner Welding Guide.

You are probably familiar with the appearance of a great aluminum weld. A skilled welder can create an aluminum weld bead that looks like a stack of dimes and is consistent throughout. Perhaps you have heard about the challenges involved with welding aluminum. This point brings to light the questions:

• Why are these really nice aluminum welds so hard to achieve?
• Why is welding aluminum so challenging?
• What welding machines are best suited for aluminum?

Aluminum Welding Equipment

This article focuses on TIG welding aluminum since it is widely used for the aluminum welding process. Just know that TIG welding is not the sole technology for the process. TIG welding and MIG welding can both achieve good welds in the aluminum material category.

The difference between TIG welding and MIG welding equipment is drastic. TIG welders use a tungsten electrode which keeps the weld puddle formed. Simultaneously, the welding operator manually dips a filler rod material into the puddle. In contrast, aluminum MIG welding equipment is specialized specifically for the process.

To use a MIG welder to weld aluminum material together, you need what is called a spool gun. The spool gun houses a coil of aluminum filler material spooled into a cartridge. This cartridge is located on the handle of the MIG welder. The reason that the aluminum filler wire must be fed through the spool gun is quite simple.

Unlike ferrous filler wire materials, the aluminum filler wire material does not have the rigidity to withstand being pushed or fed through the bends of a MIG cable up to the handle. Since using MIG spool gun is not as common in this beginner welding category, this article focuses on the TIG welding process of welding aluminum.

There is a wide array of options and features to select from while in the market for a TIG welder. Below are some of the features that separate more economical TIG welders from higher-performance TIG welders.

Economical TIG Welders

The main factors which cause a welding machine to be more economical in price are its:

• Cooling system
• Peak amperage range
• Duty cycle
• Accessories

More economical TIG welders for welding aluminum still have the minimum requirements necessary such as:

• AC current capability
• Cooling system
• Ruggedness

But these features will be limited. There is nothing wrong with using a quality TIG welder with fewer features. It is simply a matter of application.

How often will you weld aluminum?

You might not be making welds every day, multiple times a day, for extended periods; you might just need to weld a few parts together every so often. Nonetheless, economical-grade welders have their place in the market. A critical aspect of a welder used for TIG welding is its cooling capabilities.

Since aluminum naturally has a higher melting point than other ferrous materials, the welder has to achieve higher amperages. Higher amperage creates the heat necessary. More economical welders use an air cooling system. They do not have any special ways of cooling the TIG torch. For this reason, a weld cannot be extra long or large. This would require the arc to exist for longer periods of time, creating too much heat.

Economical TIG welders also cannot reach the higher amperages needed to weld extra thick pieces of material. This can be mitigated somewhat by pre-heating the workpiece but to a limited extent. Smaller welders simply don’t have the penetration power needed for those larger welds in thick aluminum materials.

Due to the heat involved when welding aluminum, you have to take breaks. Especially during a longer aluminum weld. Not doing so risks damaging your equipment. See your owner’s manual for exact duty cycle ratings. Short-duty cycles can be inconvenient when you need to perform longer welds.

In addition, the accessories which come with one of these welders are typically limited to a:

• standard welding torch
• standard foot pedal
• regulator

Tip: When considering overall costs of welding equipment, don’t forget to factor in the cost of your bottle of argon shielding gas. Pricing depends on availability in your region, but larger bottles can be expensive.

High-Performance TIG Welders

As discussed in the previous section, high-performance TIG welders for aluminum materials have everything that the economical grade welders have, but much more. High-performance TIG welders have integrated water cooling systems which dramatically decrease the build-up of heat in the torch and in the machine.

These cooling systems function largely in the same way as the cooling system in your car. This is done by reducing heat buildup in the water by passing cool air over a radiator inside the machine. These machines have a higher amperage range and a longer duty cycle. Mainly, due to the heavier duty components in the welding machine.

Accessories included with high-performance machines are generally higher-end themselves. Such as:

• Ergonomic TIG torches
• Precision gas regulators
• Precision foot pedals (with better resolution)
• Heavier duty clamps and torch accessories

Beginner welders probably don’t need this level of welding machine. Especially considering the significant increase in cost. But if budget is not a concern these welders will increase your enjoyment of the welding experience.

Aluminum Welding Procedures and Technique

Preparing your material before welding is always very important to do correctly. There are two reasons why you have to clean your raw aluminum material.

1. Aluminum naturally forms an oxide layer on its exterior surface while it is cooling off at the factory
2. Cleaning oils and contaminants on the surface left by handling the material

There are two steps to cleaning the surface of your aluminum before starting your weld

Step 1: Cleaning

Remove the oils and contaminants from the material’s surface. It is important to perform this step before any brushing. Brushing can push contaminants further into the material. You can use acetone to clean the surface of the material. Or,  other surface cleaners specifically for aluminum preparation.

Step 2: Brush the Surface

Brush the surface of the aluminum material to remove aluminum oxides. This oxide layer is usually not difficult to remove from the surface of the material using a brush. Always use a stainless-steel brush for this step. Because using a carbon steel brush will only introduce ferrous contaminants into your aluminum. Thus causing weld quality problems due to the impurities introduced.

As you can see, keeping your aluminum clean is very important. You will notice a major difference in your weld quality when welding a well-cleaned aluminum joint.

Tip: Mark your different brushes with “Steel, “Stainless,” and “Aluminum,” so you don’t get the different brushes mixed up. You don’t want to accidentally use a brush which you always use on carbon steel on your aluminum material. This will result in an impure and low-quality weld. 

Tip: Always use domestic (USA) melt source aluminum if your weld is critical. Aluminum sourced from countries overseas, especially China, frequently has impurities in the material which will result in poor weld quality and joint strength. You will see a significant difference in price between domestic and non-domestic aluminum. What you save in money with cheap materials you will sacrifice in weld quality. Most reputable online and local material suppliers will have domestic aluminum available for sale.

Step 3: Machine Preparation

Make sure your welding machine is set to your desired settings. The selector switch on your machine should be set to Alternating Current (A/C). The amperage range should be set toward the upper range of your machine. This is more precisely controlled by your foot pedal, of course.

Your TIG electrode should be pure tungsten due to the better durability and purity. The electrode should not be sharpened to a sharp point since the rough alternating current could cause the very tip of your electrode to break off and could fall into your weld. Your shielding gas should be pure argon gas for optimal weld purity and performance while welding aluminum.

Tip: An optimal weld setting that works for someone else might not work the same for you. Keep a “cheat sheet” of your best welding settings so that you can repeat your best welds. You can tell when you have laid down an excellent bead.
You will feel good about it. Now go one step further and write down that setting so you can repeat it next time. This is especially helpful when you share a machine with a coworker. You will then be able to repeat the magic!

Aluminum Welding Process

Pre-Weld Checklist

Consider this your “pre-flight” checklist, similar to how pilots ensure their aircraft is in order before taking off. Do you have all of your equipment set up for your welding operation? You should run through a checklist to make sure everything is set up and ready for your welding operation.

Your checklist should include at least the following items:

• Make sure there is nothing around your workpiece that can catch fire
• Set your amperage
• Ensure your current is set to Alternating Current (A.C.)
• Check your machine for the proper amount of coolant (if it is water-cooled)
• Tighten all connections on your TIG torch cable and hose
• Examine the electrode so that it is both in good condition and has the proper amount of “stick-out”
• Open the valve on your bottle of shielding gas
• Set your shielding gas regulator to the proper amount of flow
• Turn on and adjust your auto-darkening welding helmet
• Wear all of your PPE

Tip: Since there are so many items to remember before beginning your weld, it may be helpful to create your own list on a piece of paper and attach it to the top of your welder so you can reference it easily.

Personal Protective Equipment (PPE) Ready

Ensure that all of your Personal Protective Equipment (PPE) is in place and properly functioning. Since safety is always of the utmost importance in the field, always make sure your PPE is on your person and functioning before starting your weld. As discussed in other articles, your PPE essentials for welding are:

• Safety glasses
• Hearing protection
• Steel toe boots
• Auto-darkening welding helmet
• Welding gloves
• Leathers/flame retardant coat
• Flame-retardant headwear

Even though the above are all important to use while welding, for TIG welding aluminum you could choose to focus primarily on the following PPE items:

• Safety glasses
• Auto-darkening welding helmet
• Welding gloves

Always make sure you are wearing your safety glasses while in a welding shop. Especially while grinding TIG welding electrodes. TIG welding electrodes, typically tungsten material, need to be cleaned up using a bench grinder following any sort of contamination issues while welding. Needless to say, bits of tungsten flying through the air while grinding your electrode are very hazardous.

Helmet Shading and Gloves

Your auto-darkening helmet needs to be adjusted to the correct settings for TIG welding aluminum. Since the amperage used is typically higher than when welding other materials, you should increase the shade level to match the intensity of the arc light. Please read your welding helmet manual for instruction regarding properly adjusting your welding helmet. Additional information surrounding the potential dangers to a welder’s eyes can be read here.

Selecting and using the correct type of welding gloves for TIG welding aluminum is important. Primarily to help you avoid painful burns on your hands. While the traditional welding gloves for TIG welding are thinner calfskin leather gloves, you might want to consider a thicker glove for welding aluminum.

Some welders prefer a thicker glove similar to the popular “Mechanics” gloves. Mostly since they are made from a thicker leather material, yet still allow full range of motion. Your preference might vary. So try a pair of gloves and at the worst case, you can hold onto them for a different use if you don’t like them for TIG welding aluminum.

Best Overall

Rapicca Welding Gloves

• Reinforced Double Layer Kevlar Padding
• Guaranteed to Withstand Temperatures up to 932 F
• 16-inch Extra Long Gloves
• 1.5mm Thick Cowhide Leather

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Best Value for Money

Lincoln Electric Welding Gloves

• High Grade Leather and Soft Cotton Liner
• Kevlar Threading and Leather Reinforced Stree Points
• Inside Cuff Lined with Twill Cotton to Absorb Moisture

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Best for Stick Welding

Miller Electric Welding Gloves

• Fully Welted Seams
• 13-inch Cowhide Leather
• Comfortable Black Liner

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Visualize the Weld Path and Angles

Right before starting your weld it is always helpful to visualize the welding process. Specifically the actions you will need to take in order for your weld to be successful. It may help to close your eyes for a moment and visualize the angles which your electrode, your filler rod, your electrode handle, and your foot pedal need to be throughout your the process.

If you start your weld without this type of visualization, there is a good chance that at a corner transition of your weld you might not use the correct angles and your weld might fail. Additionally, suppose you don’t use this type of visualization method. In that case, there is a good chance that a few inches into your weld bead when you have to adjust the position of your hands you might start using an incorrect electrode angle or filler rod angle. Elite athletes use visualization techniques prior to the start of an event. Athletes use these techniques for the same reasons as welding technicians – to maintain optimal focus throughout the event.

Create Your Weld and Don’t Dwell

Using the high-frequency arc-starter function, push your foot on the foot pedal to start your arc. Your mind should be focused on the size of the puddle and where the extent of the puddle are located on either side of your joint. This is controlled with your torch angle. Get into a rhythm of creating the properly sized puddle, dipping your filer rod into the puddle, removing your filler rod, advancing your torch forward, and repeating. Even though you have to wait for your puddle to form under the welding torch, once it does, you have to move rapidly.

If you don’t have a sense of urgency while TIG welding aluminum you will end up with a:

• Weld puddle that is too big
• Heat affected zone that is out of control
• Bend in your workpiece or a blow through the workpiece altogether

This is where experience plays a big part under the welding helmet. That is knowing how to adjust your welding parameters “on the fly.” Whether this means applying less amperage via your foot pedal, adjusting your torch angle, speeding up, slowing down, or a combination of variables.

Inspection (Pass/Fail)

Beginner welders don’t typically have to be concerned with passing a weld inspection. But, they should be aware of the real-world implications. In the real-world aluminum joints exist in ultra-high requirement applications. There are aluminum welds holding together race cars, airplanes, and other life-critical purposes. Aluminum welds in these applications are scrutinized for quality before approval.

Some of the high-end inspection methods include fluorescent penetrant inspection and x-ray inspection, at a basic level, looking for cracks in the weld. A more simplistic approach which beginner welders can use is to see if the weld has any visible cracks, see if the weld is consistent from start to finish, and see if the root of the weld is the proper size. Do not be concerned if your welds don’t pass this mock inspection – simply start over again and practice until your welds look great.

Tip: If your weld is cracking down the length of the bead, your workpiece could be getting too hot or your filler rod might be an incorrect match for your base material. Either adjusting your amperage settings or performing a bit of research online to see which filler is best for your alloy of aluminum should solve this issue.

More Tips for Aluminum Welding

I have written a comprehensive guide to aluminum welding that you may find useful.

Optimal Conditions

Sometimes your technique could be spot-on, but your surrounding environment is causing your welds to suffer in quality. One environmental issue which could cause your weld quality to diminish is the wind. If there is a wind or even a breeze, your shielding gas could disappear and not properly shield your weld. Without shielding gas surrounding your weld puddle, the natural atmosphere we breathe causes porosity and unclean welds. This is the case with all welding technologies, but especially in TIG welding when welding non-ferrous materials such as aluminum, titanium, and high nickel content superalloys.

This shielding gas issue can be resolved simply by putting up screens to block the wind and/or turning up the shielding gas output. Please be cautious about blocking off ventilation from the room which you are welding in since the shielding gasses and the fumes from welding can be extremely hazardous.

Relax

Learn to relax while you are performing your weld bead. You have learned that TIG welding is a very manual process which takes ultimate concentration and skill, all of which can result in getting stressed and tense while creating your weld bead. If you intend on welding more after your first weld bead for the day, you simply won’t last if your body is tense – you will be fatigued and your subsequent weld beads will suffer.

It comes with practice, but if you put yourself in a relaxed state prior to starting your arc and continuing that relaxation through your weld, you will only see positive results. This relaxation allows you to better focus on your weld puddle, your filler dipping technique, and on your heat affected zone. In contrast, if you tense up due to panicking about your weld, you will forget to focus on your weld puddle, your filler dipping technique will go down the drain, and your heat affected zone will probably grow out of control.

Get Comfortable

Getting comfortable is one of the keys to concentrating on making a great weld. The TIG welding process typically allows the welding operator to sit at a bench and weld the workpiece in position. You should take advantage of being able to sit down and weld. Often, a weld will look poorly due to the welding operator not being comfortable. For example, a crooked wrist, a strained back, or a hurt ankle due to an out of position foot pedal can all cause the operator to be distracted and result in a poor weld.

You should turn and clamp the workpiece to a more comfortable position, get a better pad for your chair, and make sure your foot pedal is in a good spot.

These small adjustments can result in big improvements in your weld quality. Sometimes you are not able to get completely comfortable while performing your weld; for example, if you are welding out of position on a fixed workpiece. In this case, try to get as comfortable as possible stacking as many variables in your favor. Additionally, take a short break (if possible) if you are welding out of position to rest your arms or back since a fatigued welding operator typically results in poor weld quality.

Ask for Help

As the workforce in the welding industry ages and more of the workforce moves to retirement (this is a topic for another article) innumerable experienced welders would be happy to pass on the trade to someone who is willing to listen and learn. You are bound to eventually get frustrated with learning the welding process.

There are so many small techniques and tidbits of experience which you need to learn in order to master the trade.

Do not be discouraged if you cannot achieve a good-looking aluminum weld bead after three or four weeks of trying. Instead, reach out to an expert and ask for help. This help can be found in many places, whether at an instructional welding course at a vocational school or community college, senior coworkers at your job, or even from YouTube videos. The resources are out there, it is just a matter of realizing that you are not alone in being frustrated with learning TIG welding and asking for help.

Practice makes perfect

This tip might be as obvious as it sounds, but in the case of welding aluminum, it is extremely true. Welding aluminum is no less than an art form. There are numerous parameters which must be set in the machinery, and as previously discussed those parameters are dependent on different variables.

There are numerous conditions which you must be aware of while you are under your helmet and welding – experience and skill will tell you how to fix issues on the fly. TIG welding aluminum requires finesse: controlling multiple variables all at once in order to create a great weld.

Master welders will tell you that only once you think you know everything is when you actually know nothing. There is no substitute for experience in the field of welding, but education and practice will help accelerate your gain of that valuable experience.

Conclusion

Since welding aluminum is so challenging to master, it is immensely rewarding as a result. There are always opportunities in the job market for skilled welders who can successfully weld aluminum. Many of these career opportunities are either in the aerospace or the shipbuilding industries. You should weld as frequently as you can in order to continuously improve your skillset and always be optimistic about laying down a great weld.

The post A Beginners Guide to TIG Welding Aluminum appeared first on Beginner Welding Guide.