SUPERGLAZEâ„? ALUMINUM MIG WELDING GUIDE
For GMAW Welding
SUPERGLAZE ALUMINUM WIRE TECHNICAL GUIDE
CONTENTS
I. THE EXTRAORDINARY ADVANTAGES OF SUPERGLAZE . . . . . . . . . . . . . . . . . . . . . . . . .3
II. EFFECTS OF ALLOYING ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Metallurgy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Alloying Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Temper Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Chemical Composition of SuperGlaze MIG Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Electrode Description and Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Filler Alloy Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Filler Metal Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
How Alloys Effect Mechanical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10
III. HOW PHYSICAL PROPERTIES EFFECT WELDING PROCEDURES . . . . . . . . . . . . .10-13
Electrical Conductivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11
How Alloys Effect Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
CTTWD vs. Arc Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Causes and Curves for Weld Porosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13
IV. RECOMMENDED PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-16
Cleaning of Base Material and Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Welding Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Joint Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Typical Joint Geometries Aluminum MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Typical Procedures for Aluminum MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
V. PULSING AND WAVEFORM MANIPULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-18
Evolution of Power Supplies for GMAW of Aluminum . . . . . . . . . . . . . . . . . . . . . . . .17
Anatomy of a Waveform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Process Optimization via Manipulating Waveform . . . . . . . . . . . . . . . . . . . . . . . . . . .18
VI. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-20
VII. REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
ARC WELDING SAFETY REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-24
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I. THE EXTRAORDINARY ADVANTAGES Typical Competitive
Product
OF SUPERGLAZE
CONTROLLING ALLOYS
The process of making aluminum MIG wires is a complex
one, but one in which Lincoln has a clear and distinct
SuperGlaze
advantage. We are the only manufacturer that melts the “Best in Class�
raw materials to make MIG wire. First, we utilize auto-
mated tilting furnaces to efficiently produce the proper
aluminum alloys. With this equipment, we are able to
hold tight tolerances in the composition. The alloy is
carefully refined prior to casting to minimize hydrogen,
5356 Wire Surface
hydrogen alkaline metals, and inclusions. Consistent
Magnified 60x
chemical composition produces superior arc stability.
CONTINUOUS CASTING
Second, we use a continuous casting process specially
configured for high alloy materials. This process keeps Standard SuperGlaze Products
the surface free from imperfections and impurities.
SuperGlaze Available
Minimal surface contaminants reduces risk of porosity in
Alloys Diameters
welds.
1100
DRAWING THE WIRE .030 (0.8mm)
4043
.035 (0.9mm)
In the last step of the process, we use advanced wire 4047
.040 (1.0mm)
5183
drawing technology to preserve both surface integrity 3/64� (1.2mm)
5356
and internal soundness. This is also the step where our 1/16� (1.6mm)
5554
3/32� (2.4mm)
proprietary process, SuperGlaze, is used for unmatched 5556
product quality. It is also the only MIG wire on the
market that is shaved twice! This smooth surface finish
gives superior feedability.
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For cast alloy designations, a three digit number plus
II. EFFECTS OF ALLOYING ELEMENTS
one decimal is used to designate each cast alloy. The
METALLURGY first digit indicates the principal alloying element. The
cast alloy designations lack the modification digit of the
To understand aluminum, we must first understand
wrought designations. Instead modifications are indicat-
some basics about aluminum metallurgy. Aluminum can
ed by a prefix letter (A,B,C, etc.). The second and third
be alloyed with a number of different elements, both
digits form the arbitrary number identifying the specific
primary and secondary, to provide improved strength,
alloy. The decimal indicates whether the alloy composi-
corrosion resistance and/or general weldability.
tion is for the final casting (.0), or for the ingot (.1 or .2
The primary elements that alloy with aluminum are depending on purity limits).
copper, silicon, manganese, magnesium and zinc. It is
important to note that these alloys fall into two classes:
Cast Aluminum Alloys:
heat-treatable or nonheat-treatable.
Aluminum
Heat-treatable alloys are those that can be heat-treated
to increase their mechanical properties. To heat-treat an
alloy means heating it at a high temperature, putting the
alloying elements into solid solution and then cooling it
at a rate which will produce a supersaturated solution.
Si+Cu
The next step in the process is to maintain it at a lower Al Cu and/or Mg Si Mg Zn Sn Other
temperature long enough to allow a controlled amount 1XX.X 2XX.X 3XX.X 4XX.X 5XX.X 7XX.X 8XX.X 9XX.X
of precipitation of the alloying elements.
With the nonheat-treatable alloys it is possible to
increase strength only through cold working or strain
NonHeat-Treatable Heat-Treatable
hardening. To do this, a mechanical deformation must
occur in the metal structure, resulting in increased
resistance to strain, producing higher strength and ALLOYING ELEMENTS
lower ductility.
Pure Aluminum (1XXX series) Contains no alloying
Two designations have been developed to identify elements, and is considered nonheat-treatable. It is
aluminum alloys. The most commonly used alloys are used primarily in chemical tanks and pipe because of its
normally identified using wrought alloy designations. superior corrosion resistance. This series is also used in
This designation is a four digit number where the first electrical bus conductors because of its excellent elec-
digit indicates the principal alloying element or elements. trical conductivity. Easily welded with 1100 and 4043
If the second digit is not zero, then the original registered filler wires.
alloy has been modified in some way. The third and
fourth digits are arbitrary numbers that identify the Copper (2XXX series) Provides high strength to
specific alloy, as shown in Table 1 on page 6. The aluminum. This series is heat-treatable and mainly used
exception to this is with the 1XXX series alloys that are in aircraft parts, rivets and screw products. Most 2XXX
almost pure aluminum. For this series, these digits series alloys are considered poor for arc welding
indicate the degree of purity above 99.00%. For because of their sensitivity to hot cracking. These alloys
example, 1080 is 99.80% pure aluminum. are generally welded with 4XXX series filler wires, such
as 4043 or 4145, which have low melting points to
reduce the probability of hot cracking. An exception to
this is alloys 2014, 2219 and 2519, which are easily
Wrought Aluminum Alloys:
welded with 4043 or 2319 filler wire. These alloys are
Aluminum widely used in welded fabrication.
Manganese (3XXX series) Yields a nonheat-treatable
series used for general-purpose fabrication and build-
up. Moderate in strength, the 3XXX series is used for
Al Cu Mn Si Mg Mg/Si Zn Other forming applications including utility and van trailer
1XXX 2XXX 3XXX 4XXX 5XXX 6XXX 7XXX 8XXX
sheet. It is improved through strain hardening to provide
good ductility and improved corrosion properties.
Typically welded with 4043 or 5356 filler wire, the 3XXX
series is excellent for welding and not prone to hot
NonHeat-Treatable Heat-Treatable
cracking. Its moderate strengths do prevent this series
from being used in structural applications.
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Silicon (4XXX series) Silicon reduces the melting point TEMPER DESIGNATIONS
of the aluminum and improves fluidity. Its principle use is
(In general, not relevant for ordering filler wires)
as filler metal. The 4XXX series has good weldability and
The Aluminum Association Temper Designation System
is considered a nonheat-treatable alloy. Alloy 4047 is
is used for all forms of wrought and cast aluminum and
becoming the alloy of choice in the automotive industry
aluminum alloys except ingots. Some aluminum alloys
as it is very fluid and good for brazing and welding.
achieve temper by strain hardening and some by heat
treatment. In general the 1XXX, 3XXX, 4XXX and 5XXX
Magnesium (5XXX series) When added to aluminum,
series wrought alloys are strain hardenable. The 2XXX,
magnesium has excellent weldability with a minimal loss
6XXX and 7XXX series wrought alloys are heat-treatable.
of strength and is basically not prone to hot cracking. In
The 2XX.X, 3XX.X, 4XX.X and 7XX.X series cast alloys
fact, the 5XXX series has the highest strength of the
are heat-treatable. Strain hardening is not generally
nonheat-treatable aluminum alloys. It is used for chemi-
applied to castings.
cal storage tanks and pressure vessels at elevated
Basic temper designations are:
temperatures as well as structural applications, railway
cars, dump trucks and bridges because of its corrosion “F� As fabricated.
resistance.
“O� Annealed. For lower strength condition, improved
ductility and dimensional stability.
Silicon and Magnesium (6XXX series) This medium
strength, heat-treatable series, is primarily used in auto- “H� Strain-hardened. Applies to wrought products
motive, pipe, railings, and structural and extruding which are strengthened by stain-hardening
applications. The 6XXX series is somewhat prone to hot through cold-working.
cracking, but this problem can be overcome by the
“W� Solution heat-treated. An unstable temper
correct choice of joint and filler metal. Can be welded
applicable only to alloys which age spontaneously
with either 5XXX or 4XXX series without cracking �
at room temperature after solution heat-treatment.
adequate dilution of the base alloys with selected filler
Solution heat-treatment involves heat treating the
wire is essential. A 4043 filler wire is the most common
alloy to 1000°F (538°C) to bring the alloying ele-
for use with this series.
ments into solid solution, followed by rapid
quenching to achieve a super saturated solution
Zinc (7XXX series) Zinc added to aluminum with mag-
at room temperature.
nesium and copper produces the highest strength heat-
treatable aluminum alloy. It is primarily used in the air- “T� Thermally treated to produce stable tempers
craft industry. The weldability of the 7XXX series is com- other than “F�, “O� or “H�.
promised in higher copper grades, as many of these T1 Naturally aged
grades are crack sensitive (due to wide melting ranges T2 Cold worked and naturally aged
and low solidus melting temperatures). Grades 7005 T3 Solution heat treated, cold worked and
and 7039 are weldable with 5XXX filler wires. They are naturally aged
widely used for bicycle frames and other extruded appli- T4 Solution heat treated and naturally aged
cations. T5 Artificially aged
T6 Solution heat treated and artificially aged
Other (8XXX Series) Other elements that are alloyed T7 Solution heat treated and stabilized
with aluminum (i.e. lithium) all fall under this series. Most T8 Solution heat treated, cold worked and
of these alloys are not commonly welded, though they artificially aged
offer very good rigidity and are principally used in the T9 Solution heat treated, artificially aged and
aerospace industry. Filler wire selection for these heat- cold worked
treatable alloys include the 4XXX series. T10 Cold worked and artificially aged
An example of a complete designation is: 2014-T6. This
In addition to the primary aluminum alloying elements,
means that it is alloyed with copper (2XXX series) and
there are a number of secondary elements, which
the T6 refers to the fact that it is solution heat-treated
include chromium, iron, zirconium, vanadium, bismuth,
and artificially aged.
nickel and titanium. These elements combine with alu-
minum to provide improved corosion resistance,
increased strength and better heat treatability.
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CHEMICAL COMPOSITION OF SUPERGLAZE
MIG WIRES
wires are intended for GMAW (Gas Metal Arc Welding) .
Lincoln Electric SuperGlaze Aluminum alloy wires are
with Argon or Helium/Argon gas mixtures.
manufactured to meet requirements as specified in
AWS/ANSI A5.10 Specification of Bare Aluminum Alloy
Table 1 shows the chemical composition of standard
Welding Electrodes. All SuperGlaze Aluminum alloy
and special SuperGlaze MIG wires that are available.
TABLE 1
WIRE CHEMICAL COMPOSITION (%)
(Single Values are Maximum, except of Aluminum)
AWS A5.10-92
ASME SFA-5.10
Others(g)
Mn Si Fe Mg Cr Cu Ti Zn Be Al
Classification
ER1100 &
0.05 � � 0.05-0.20 � 0.10 0.05 99.0
(b) (b)
Alloy 1050(a)(h)
0.05(e)
ER2319(a) 0.20-0.40 0.20 0.30 0.02 � 5.8-6.8 0.10-0.20 0.10 rest
(d)
ER4043 0.05 4.5-6.0 0.8 0.05 � 0.30 0.20 0.10 0.05 rest
(d)
ER4047 0.15 11.0-13.0 0.8 0.10 � 0.30 � 0.20 0.05 rest
(d)
ER4643(a) 0.05 3.6-4.6 0.8 0.10-0.30 � 0.10 0.15 0.10 0.05 rest
(d)
Alloy 5052(a)(h) 0.10 0.25 0.40 2.2-2.8 0.15-0.35 0.10 � 0.10 0.05 rest
(d)
Alloy 5056(a)(h) 0.05-0.20 0.30 0.40 4.5-5.6 0.05-0.20 0.10 � 0.10 0.05 rest
(d)
Alloy 5087(h) 0.6-1.0 0.25 0.40 4.3-5.2 0.05-0.25 0.05 0.15 0.25 0.10-0.20 rest
(d)
Alloy 5154(a)(h) 0.10 0.25 0.40 3.1-3.9 0.15-0.35 0.10 0.20 0.20 0.05 rest
(d)
ER5183 0.50-1.0 0.40 0.40 4.3-5.2 0.05-0.25 0.10 0.15 0.25 0.05 rest
(d)
ER5356 0.05-0.20 0.25 0.40 4.5-5.5 0.05-0.20 0.10 0.06-0.20 0.10 0.05 rest
(d)
ER5554(a) 0.50-1.0 0.25 0.40 2.4-3.0 0.05-0.20 0.10 0.05-0.20 0.25 0.05 rest
(d)
ER5556(a) 0.50-1.0 0.25 0.40 4.7-5.5 0.05-0.20 0.10 0.05-0.20 0.25 0.05 rest
(d)
ER5654(a) 0.01 3.1-3.9 0.15-0.35 0.05 0.05-0.15 0.20 0.05 rest
(c) (c) (d)
Alloy 5754(a)(h) 0.25 0.40 2.6-3.6 0.05-0.30 0.05 0.15 0.20 0.05 rest
(f) (d)
(a) SuperGlaze alloy available on a made-to-order basis. (f) Mn + Cr = 0.10 - 0.60% (minimum Mn of 0.20% or
(b) Silicon + Iron shall not exceed 0.95%. minimum Cr of 0.1%).
(c) Silicon + Iron shall not exceed 0.45%. (g) Total “others� shall not exceed 0.15%.
(d) Beryllium shall not exceed 0.0008%. (h) Not included in AWS A5.10, ASME SFA-5.10.
(e) Vanadium content shall be 0.05 - 0.15% and
Zirconium content shall be 0.10 - 0.25%.
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amounts of magnesium, manganese, and/or zirconium,
ELECTRODE DESCRIPTION AND SELECTION
are capable of meeting minimum required welded ten-
ER1100 The 1XXX series of filler alloys make the soft-
sile stresses for the higher strength 5XXX alloys.
est electrode wire and require extra care to ensure good
ER5356, ER5556 and ER5183 and are also suitable for
feeding. Electrical and chemical applications for aluminum
welding the 5XXX aloys to 6XXX and weldable 7XXX
often use base metal with little or no alloying elements
alloys. However, since these alloys contain magnesium
and filler alloys for these are often required to have simi-
levels above 3%, they are not suitable for use in appli-
lar compositions. ER1100 is suitable in most cases
cations where the service temperature exceeds 150°F
although it contains a small amount of Cu.
(65°C). Prolonged exposure above 150°F (65°C) will
ER2319 This alloy is designed to weld the 2XXX alloys sensitize these alloys to stress corrosion cracking and
2219 and 2519. While these alloys can also be welded result in premature failure. For the same reason, post
with ER4043, ER2319 gives significantly higher welded weld stress relieving or post weld aging operations
properties. should not be performed when these filler alloys are used.
ER5554 is intended as a matching filler alloy when
ER4043, ER4047 ER4043 was developed for the
welding 5454 base materials. This alloy is a lower
welding of heat-treatable base alloys and more specifi-
magnesium content alloy and is often used for auto-
cally the 6XXX series alloys. It has a lower melting point
motive wheels, over the road trailers, and rail tank cars
and more fluidity than the 5XXX series filler alloys, and is
where the weld filler metal chemistry must closely match
preferred by most welders because of its operating
the base material chemistry to maximize corrosion
characteristics and is less sensitive to weld cracking
performance.
with the 6XXX series base alloys. These alloys are not
suitable for welding Al-Mg alloys (specifically alloys
FILLER ALLOY SELECTION
5083, 5086, 5456) because excessive magnesium-sili-
cide (Mg2Si) may develop in the weld structure to Selection of the most suitable filler alloy for each weld-
decrease ductility and increase crack sensitivity. ing application could be simple when structures are to
ER4047 was developed as a brazing filler metal to take be built of the common alloys using common fabrication
advantage of its much lower melting point and higher practices and when they are to be exposed to common
fluidity, but it is used as a welding filler alloy also. service conditions. However, special service conditions
ER4047 can be used as a substitute for ER4043 to pro- and/or special base alloys may require special filler
vide increased Si in the weld metal to minimize hot alloys. The following metal selection methodology
cracking and to produce higher fillet weld shear should be followed:
strengths. All 4XXX series filler alloys are suitable for
1. Determine base metals and thicknesses.
sustained elevated temperature service, i.e. above
2. Determine process and joint geometry.
150°F (65°C).
3. Determine requirements:
ER4643 This alloy is designed for one purpose only. Cracking resistance,
There is enough magnesium added to this alloy so that it Weld metal strength and ductility.
will respond to heat treatment. It is designed for use on Corrosion resistance,
weldments which will be completely re-heat treated (ie, Weld performance at elevated temperatures,
solution heat treated, quenched and aged) after welding Weld metal fluidity.
and will provide the highest joint strength of any of the Weld metal color match.
filler metals under these circumstances. 4. For “nonheat-treatable alloys�: use filler selection
charts with attention to requirements. Note that
ER5356, ER5183, ER5554, ER5556, ER5087 These
Medium Mg 5XXX materials such as 5052 can be
alloys are designed for the welding of 5XXX series base
sensitive to hot cracking. Dilution may need to be
alloys to themselves and other alloys. Because of their
considered where strength is important.
higher hardness and strength, the feedability of the
For “heat-treatable alloys�: Dilution, hot cracking,
5XXX filler alloys in GMAW is significantly better than
HAZ cracking, ductility and heat treatment after
that of ER4043 or ER4047.
welding needs to be considered in addition to
ER5356 is the most commonly used 5XXX filler alloy. It requirements.
is suitable for welding any of the 5XXX base materials.
The Filler Metal Guide, Table 2 on page 8, covers both
However, when welding some of the stronger 5XXX
wrought and cast alloys.
alloys, such as 5083 or 5654 where welded tensile
strengths of 40ksi (276 MPa) or greater are required,
ER5356 may not be quite strong enough.
In cases where 5356 doesn’t meet the minimum
required tensile stress, filler alloys ER5556, or ER5183
can be used. These alloys, which contain increased
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TABLE 2 - FILLER METAL GUIDE
6061
356.0 6063
319.0 357.0 7005 k 6101
333.0 359.0 511.0 7039 6201 1060
354.0 413.0 512.0 710.0 6151 1070
Base 355.0 444.0 513.0 711.0 6351 5154 5052 5005 2219 2014 1100 1080
Metal 380.0 443.0 514.0 712.0 6070 6951 5456 5454 5254 a 5086 5083 5652 a 5050 3004 2519 2036 3003 1350
1060
1070 4145 4043 5356 5356 4043 4043 5356 4043 5356 5356 5356 4043 1100 4043 4145 4145 1100 1188
1080 c, i i, f c,e,i c,e,i i i c i c,e,i c c i c c j
1350
1100 4145 4043 5356 5356 4043 4043 5356 4043 5356 5356 5356 4043 4043 4043 4145 4145 1100
3003 c,i i,f c,e,i c,e,i i i c e,i c,e,i c c e,i e e c
2014 4145 4145 4145 4145 4145 4145
2036 g g g
2219 4145 4145 4043 4043 4043 4043 4043 4043 4043 4043 4043 4043 4043 4043 2319
2519 g,c,i c,i i i f,i f,i i i i c,f,i
3004 4043 4043 5654 5356 4043 4043 5356 5654 5654 5356 5356 4043 4043 4043
i i b e e b e b b e e e,i e e
5005 4043 4043 5654 5356 4043 4043 5356 5654 5654 5356 5356 4043 4043
5050 i i b e e b e b b e e e,i d,e
5052 4043 4043 5654 5356 5356 5356 5356 5654 5654 5356 5356 5654
5652 i b,i b e b,c b,c b b b e e a,b,c
5083 5356 5356 5183 5356 5356 5183 5356 5356 5356 5183
c,e,i e e e e b e e e e
5086 5356 5356 5356 5356 5356 5356 5356 5356 5356
c,e,i e e e e e b b e
5154 4043 5654 5356 5356 5356 5356 5654 5654
5254 a b,i b b b,c b,c b a a,b
5454 4043 4043 5654 5356 5356 5356 5356 5554
i b,i b b b,c b,c b c,e
Notes: All filler materials are listed in AWS specification A5.10.
a. Base metal alloys 5652 and 5254 are used for hydrogen
5456 5356 5356 5556 5356 5356 5556
peroxide service, 5654 filler metal is used for welding both
c,e,i e e e e e
alloys for low temperature [150°F (65°C)] service.
6061 b. 5183, 5356, 5454, 5556 and 5654 may be used. In some
6063 cases they provide improved color match after anodizing,
6101 4145 4043 5356 5356 4043 4043 highest weld ductility and higher weld strength. 5554 is
6201 c,i f,i b,c b,c,i b,i b,i
suitable for elevated temperature service.
6151
c. 4043 may be used for some applications.
6351
d. Filler metal with the same analysis as the base metal is
6951
sometimes used.
6070 4145 4043 5356 5356 4043 e. 5183, 5356 or 5556 may be used.
c,i f,i c,e c,e,i e,i f. 4145 may be used for some applications.
g. 2319 may be used for some applications.
7005 k
i. 4047 may be used for some applications.
7039
j. 1100 may be used for some applications.
710.0 4043 4043 5356 5356
k. This refers to 7005 extrusions only.
711.0 i b,i b e
712.0
511.0 ADDITIONAL GUIDELINES
512.0 4043 5654
1. Service conditions such as immersion in fresh or salt water,
513.0 b,i b,d
exposure to specific chemicals, or exposure sustained high
514.0
temperature (over 150°F) may limit the choice of filler metals.
Filler alloys 5356, 5183, 5556 and 5654 are not recommended
356.0
357.0 for sustained elevated temperature service.
359.0 4145 4043 2. Guide lines in this table apply to gas shielded arc welding
413.0 c,i d,i
processes.
444.0
3. Where no filler metal is listed, the base metal combination is
443.0
not recommended for welding.
319.0
333.0
354.0 4145 The serviceability of a product or structure utilizing this type of information is and must be the sole responsi-
bility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the
355.0 d,c,i
results obtained in applying this type of information. These variables include, but are not limited to, welding
380.0
procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements.
-8-
When T4 or T6 materials are welded, the heat of weld-
HOW ALLOYS EFFECT MECHANICAL PROPERTIES
ing affects the properties in the HAZ, reducing them.
The weld deposit is a mixture of the filler metal and base Properties are usually not reduced all the way down to
metal. Strength, ductility, resistance to weld cracking, the “O� temper. It is difficult to give a general rule
corrosion resistance, heat-treatability and other proper- regarding the reduction in properties. The specific value
ties may be influenced by the amount of dilution of the depends on the alloy and temper under consideration.
weld metal by the base metal. Dilution is a function of However, as an example, 6061-T6 is required to have a
joint design, welding process and welding procedure. minimum utlimate tensile strength of 40 ksi (276 MPa)
Weld cracking tendencies are generally reduced by before welding. In the welded condition, most codes
keeping base alloy dilution of the weld metal to a require a minimum tensile stress of 24 ksi (165 MPa), so
minimum. Edge prepared joints reduce dilution of the that the reduction can be significant.
weld by base metal and thus reduce the possibility of
However, it is possible to restore the mechanical prop-
hot cracking. In general, preheating should be avoided,
erties, at least in part, by heat treating after welding.
multiple passes are preferred over fewer passes, and
Alloys welded in the T6 temper will show a slight
welding speeds should be as high as practical.
improvement in strength if they are aged after welding at
Typical mechanical properties of gas shielded arc approximately 400°F (204°C) for one hour. A much
welded butt joints in nonheat-treatable and heat-treatable larger improvement will be observed if the material is
alloys are listed in Table 3 on page 10. welded in the T4 temper and aged at 400°F (204°C) for
one hour after welding. Finally, with the proper choice of
In examining Table 3, it is clear that the welded
weld filler alloy, the welded assembly can be re-solution
strengths of most aluminum alloys are lower than the
aged, quenched, and aged to obtain the full T6 proper-
tensile strength of the starting material. In general, it is
ties. This last course of action is clearly not always prac-
not possible when welding aluminum alloys, to produce
tical, especially for large structures, but may be practical
welds as strong as the parent material. In order to
for smaller ones.
understand why this is so, some of the metallurgy of
heat-treatable and nonheat-treatable aluminum alloys Almost all alloys, except 7XXX, of the common aluminum
must be discussed. alloys can be welded without impairing their corrosion
resistance. Also, in general the choice of welding
The nonheat-treatable alloys, (1XXX, 3XXX, 4XXX and
process does not influence corrosion resistance.
5XXX), are not hardenable by heat treatment. They
come off the hot mill, are annealed in a large furnace to The excellent corrosion resistance of the 1XXX, 3XXX,
obtain the “O� temper condition, and then are cold 4XXX and 5XXX series nonheat-treatable alloys is generally
rolled (or otherwise cold worked) to strengthen them. If not affected by welding. Joints involving combinations
they are welded, the heat of welding acts as a local of these alloys also have good corrosion resistance. In
annealing treatment for the heat affected zone (HAZ). prolonged service at elevated temperatures [above
The mechanical properties in the HAZ are those of the 150°F (65°C)] of 5XXX series alloys containing more
annealed (ie “O� temper) material. It makes no difference than 3% magnesium however, these alloys eventually
what temper the material is in before welding. After become sensitive to stress corrosion. In this type of ser-
welding, the properties are those of the “O� temper. vice lower magnesium content alloys like 5454 should
Therefore, although welds in “O� temper materials will be used.
be as strong as the starting material, welds in materials
The aluminum-magnesium-silicon heat-treatable alloys
in other tempers will be weaker, sometimes significantly,
such as 6061 and 6063 have generally good corrosion
than the starting material. There is no practical wayto
resistance, unwelded or welded. However, immersed in
restore the strength lost during welding. There is no
an electrolyte such as sea water, the HAZ may corrode
heat treatment which will help.
preferentially.
The situation when using heat-treatable alloys, (2XXX,
The 2XXX and 7XXX series heat-treatable alloys,
6XXX and 7XXX), is somewhat more complex. These
containing substantial amounts of copper and zinc and
alloys are heat treated at the mill by holding at approxi-
some magnesium, may have corrosion resistance
mately 1000°F (538°C) for a short time. This is called a
lowered by the heat of welding. Grain boundary
solution heat treatment. The alloy is then quenched,
precipitation in the HAZ creates a difference in electrical
usually in water. If the process is stopped at this point,
potential from the remainder of the weld metal and, if
the material is said to be in the T4 (naturally aged)
there is an electrolyte present, selective corrosive attack
temper. However, the material can be further increased
on the grain boundaries is likely to occur. Postweld
in strength by performing an aging heat treatment at
heat-treatment provides a more homogeneous structure
approximately 400°F (204°C) for one hour. At this point,
and improves the corrosion resistance of these alloys.
the material is said to be in the T6 temper. Most heat-
However, these are not the alloys of choice where
treatable alloys are sold in this temper.
corrosion resistance is of primary importance.
-9-
TABLE 3
TYPICAL AS-WELDED MECHANICAL PROPERTIES OF GMAW WELDED BUTT JOINTS
Elongation
Base Filler Tensile Strength Yield Strength Tensile Free Bend
Alloy Alloy (ksi) (MPa) (ksi) (MPa) (%) (%)
Nonheat-Treatable Alloys
1100 1100 13 90 4.5 31 29 54
3003 1100 16 110 7 48 24 58
5005 5356 16 110 7 48 15 32
5050 5356 23 158 8 55 18 36
5052 5356 28 193 13 90 19 39
5083 5183 43 296 24 165 16 34
5086 5356 39 269 17 117 17 38
Heat-Treatable Alloys
2219-T87 2319 35 241 26 179 3 15
6061-T6 4043 27 186 18 124 8 16
6061-T6 5356 30 207 19 131 11 25
6063-T6 4043 20 138 12 83 8 16
7005-T53 5556 44 303 25 172 10 33
-10-
III. HOW PHYSICAL PROPERTIES EFFECT WELDING PROCEDURES
ELECTRICAL CONDUCTIVITY conductivity. For example, when compared to copper,
“pure� aluminum (ER1100) conducts electricity only
Physical properties of various aluminum alloys vary
60% as well. When silicon and magnesium are added,
more dramatically than with most other materials. One
such as in ER4043 and ER5356, the conductivity can
of the most important differences is in their electrical
drop to about 40% and 30% respectively versus copper.
CHART 1
100 (100%)
Electrical Conductivity
80
60
(59%)
%
40
(42%)
(29%)
20
0
Copper 1100 4043 5356
This difference in conductivity has a significant effect on and voltage, the wire feed speed of the ER4043 alloy is
welding procedures. As shown in chart 2, ideal about 17% less. Therefore, if published procedures are
procedures for these two alloys have different wire feed being used in developing or setting procedures, it is
speed/amperage curves. In fact, when these 3/64� important to know what alloy was used when they were
(1.2mm) diameter wires are running at the same current originally developed.
CHART 2
WFS vs. AMPS
550
500
450
400
WFS 350
(in./min)
3/64� 5356
300
3/64� 4043
250
200
150
150 175 200 225 250
AMPS
5356 4043
Amps WFS Amps WFS
150 325 150 270
175 385 175 315
200 440 200 360
225 495 225 410
250 545 250 460
-11-
CTTWD VS. ARC LENGTH weld. When the distance from the contact tip to work
distance (CTTWD) is increased as shown below, the arc
Aluminum has a much higher electrical conductivity than
length remains about the same. This means that the
other materials. The longer stickout of an aluminum
welding technique that operators may have learned to
wire, produces almost the same resistance in the weld-
cool off the arc, while welding ferrous materials, will not
ing circuit as a short stickout. This means that variations
be effective. However, in general, a short arc length is
in stickout have little effect on the arc and thus, the
required to produce good shielding gas coverage.
FIGURE 2
3/4"
(19.0mm)
1/2"
(12.7mm)
1/4"
(6.4mm)
-12-
FIGURE 3
CAUSES OF AND CURES FOR WELD POROSITY
EFFECT OF SHIELDING GAS
The most common defect encountered in welding
aluminum is porosity in the weld. Aluminum welds are
much more prone to exhibit porosity than are steel
100% Argon
100% Argon
welds. This is because molten aluminum has a very high
solubility and affinity for hydrogen. While the weld is
being made, it will absorb any hydrogen in the area.
However, solid aluminum has almost no solubility for
hydrogen, so as the weld solidifies, it tries to reject any 100% Helium
100% Helium
dissolved hydrogen. If it can, there is no problem. If
there is too much dissolved or if the weld solidifies too
quickly, it forms porosity in the weld.
Additionally, the addition of helium to the argon shielding
Where does the hydrogen come from? There are two gas can reduce porosity levels. Although the mechanism
primary sources; breakdown of hydrocarbons (ie, oils for this phenomenon isn’t well understood, it can be
and greases) in the arc and breakdown of water vapor seen in Figures 4 and 5. Below are two broken fillet
in the arc. In order to minimize porosity, good “house- welds made with the same SuperGlaze aluminum MIG
keeping� practices must be followed. These include: wire, same equipment, and same procedures. The only
difference was that the weld in Figure 4 was made using
� Preweld cleaning to remove oils and greases from the
pure argon gas and Figure 5 was made using 75% argon
base material.
/25% helium.
� Make sure there are no water leaks in water-cooled
torches.
� Never run water-cooled torches directly from a city
water tap. This water is cold and will cause conden-
sation in the torch cable.
� Don’t move material inside when it is cold outside and
weld on it immediately. Condensation can form on the
surface of the material.
� Don’t allow excess drafts in the welding area. Put up
screens to keep drafts away.
� Use only welding grade shielding gas with a dewpoint
no higher than -70°F (-56°C). FIGURE 4
� Make sure the welding wire doesn’t have residual
drawing lubricant on its surface.
� Use a slight leading angle (10 to 15 Degrees), but
don’t let the lead angle become excessive.
� When welding vertically, always weld vertical up.
Vertical down welding causes increased weld porosity.
� Be sure to remove heavy oxides, and especially water
stains, before welding. These oxides can become
hydrated and cause porosity.
� Shielding gases for welding aluminum are either pure
argon or argon/helium mixtures. The addition of helium
causes the arc voltage to rise, the arc to become
FIGURE 5
hotter, and the penetration profile to become wider, as
shown in Figure 3.
-13-
JOINT GEOMETRY
IV. RECOMMENDED PROCEDURES
Typical joint geometrics for semiautomatic MIG welding
CLEANING BASE MATERIAL
are shown in Figure 8 on page 15. Factors affecting the
The hydrated aluminum oxides or hydrocarbon contam- choice of the joint geometry include metal thickness,
ination on the surface of the base material is a problem whether backing is to be used (and if so, what kind), the
with aluminum alloys, more so with the 5XXX series welding position and whether welding is to be done
materials. from one side of the joint, mostly from one side, or
about equally from both sides.
Wire brush, using stainless steel hand or power brushes
to remove hydrated aluminum oxides. These oxides Where intermittent welding is to be used, only deviation
have a metling temperatures of 3720°F (2049°C), but from the regular pattern of torch travel is recommended.
the base metal melts much lower at about 1200°F GMAW (MIG) welding of aluminum normally leaves a
(649°C). With the lower melting point, it is easier to start crater at the end of the weld, as illustrated in Figure 6
an arc as well as get adequate penetration on clean below. This crater is prone to cracking which, in turn,
material. This oxide is also very abrasive and second in could initiate fracture in the intermittent weld.
hardness to diamonds. Aluminum oxides are used for
One method of avoiding this problem is to reverse the
grinding wheels and sandpaper grit. This abrasion level
direction of welding at the end of each tack or intermit-
is terrible on liners and it is not electrically conductive as
tent weld, so that the crater is filled, as shown in Figure
well. Because of this, care should be taken to remove
7. Other techniques for eliminating cracking problems of
surface oxides in the welding joint and where the work
the crater area are:
is grounded.
1. Use run-on and run-off tabs.
Lubricants are sometimes used on the surface of
2. Break the arc and restrike it to fill the crater.
aluminum to form, draw and to protect its surface.
3. Use special circuitry and power source control to
These hydrocarbons contain hydrogen and they should
produce a specific rate of arc decay.
be removed prior to welding. Acetone can be used in
this case and it should be as effective in removing
surface oils. FIGURE 6
It is important to start with clean base material in alu-
minum and some of the techniques used to clean off
aluminum oxide, such as a stainless steel bristle wire
brush, solvents and etching solutions.
WELDING PARAMETERS
Principal factors for consideration in the GMAW (MIG)
welding of aluminum are thickness of plate, alloy and
type of equipment available. Typical procedures for
GMAW (MIG) welding of various joint designs in alu-
The finish of a MIG weld in aluminum leaves a crater
minum sheet and plate are given in Tables 4 and 5, on
that is very susceptible to cracking.
page 16. The data supplied is approximate and is
intended to serve only as a starting point. For each
application, an optimum set of welding conditions can FIGURE 7
be established from these procedures.
It is considered good practice to prepare prototype
weldments in advance of the actual production so that
welding conditions can be determined on the prototype.
It is further recommended that welders practice before-
hand under simulated production conditions. This helps
avoid mistakes caused by lack of experience.
Doubling back at the end of a MIG weld eliminates the
crater and the cracking problems that usually
accompany it.
-14-
FIGURE 8 - TYPICAL JOINT GEOMETRIES FOR SEMIAUTOMATIC ALUMINUM MIG WELDING.
-15-
TABLE 4 - TYPICAL SEMIAUTOMATIC ALUMINUM MIG PROCEDURES FOR GROOVE WELDING
Arc Approx.
Metal Joint Electrode Arc Argon Travel Electrode
DC (EP)(3) Voltage(3)
Thickness Weld Edge Spacing Weld Diameter Gas Flow Speed Consump.
Position(1) Preparation(2)
(In.) (In.) Passes (In.) (Amps) (Volts) (cfh) (ipm/pass) (lb/100 ft.)
1/16 F A None 1 .030 70-110 15-20 25 25-45 1.5
F G 3/32 1 .030 70-110 15-20 25 25-45 2
3/32 F A None 1 .030-3/64 90-150 18-22 30 25-45 1.8
F, V, H, O G 1/8 1 .030 110-130 18-23 30 25-30 2
1/8 F, V, H A 0-3/32 1 .030-3/64 120-150 20-24 30 24-30 2
F, V, H, O G 3/16 1 .030-3/64 110-135 19-23 30 18-28 3
3/16 F, V, H B 0-1/16 1F, 1R .030-3/64 130-=175 22-26 35 24-30 4
F, V, H F 0-1/16 1 3/64 140-180 23-27 35 24-30 5
O F 0-1/16 2F 3/64 140-175 23-27 60 24-30 5
F, V H 3/32-3/16 2 3/64-1/16 140-185 23-27 35 24-30 8
H, O H 3/16 3 3/64 130-175 23-27 60 25-35 10
1/4 F B 0-3/32 1F, 1R 3/64-1/16 175-200 24-28 40 24-30 6
F F 0-3/32 2 3/64-1/16 185-225 24-29 40 24-30 8
V, H F 0-3/32 3F, 1R 3/64 165-190 25-29 45 25-35 10
O F 0-3/32 3F, 1R 3/64-1/16 180-200 25-29 60 25-35 10
F, V H 1/8-1/4 2-3 3/64-1/16 175-225 25-29 40 24-30 12
O, H H 1/4 4-6 3/64-1/16 170-200 25-29 60 25-40 12
3/8 F C-90° 0-3/32 1F, 1R 1/16 225-290 26-29 50 20-30 16
F F 0-3/32 2F, 1R 1/16 210-275 26-29 50 24-35 18
V, H F 0-3/32 3F, 1R 1/16 190-220 26-29 55 24-30 20
O F 0-3/32 5F, 1R 1/16 200-250 26-29 80 25-40 20
F, V H 1/4-3/8 4 1/16 210-290 26-29 50 24-30 35
O, H H 3/8 8-10 1/16 190-260 26-29 80 25-40 50
3/4 F C-60° 0-3/32 3F, 1R 3/32 340-400 26-31 60 14-20 50
F F 0-1/8 4F, 1R 3/32 325-375 26-31 60 16-20 70
V, H, O F 0-1/16 8F, 1R 1/16 240-300 26-30 80 24-30 75
F E 0-1/16 3F, 3R 1/16 270-330 26-30 60 16-24 70
V, H, O E 0-1/16 6F, 6R 1/16 230-280 26-30 80 16-24 75
(1) F - Flat, V = Vertical, H = Horizontal, O = Overhead.
(2) See joint designs in Figure E on page 14.
(3) For 5XXX series electrodes use a welding current in the high side of the range and an arc voltage in the lower portion of the
range. 1XXX, 2XXX and 4XXX series electrodes would use the lower currents and higher arc voltages.
TABLE 5 - TYPICAL SEMIAUTOMATIC ALUMINUM MIG PROCEDURES FOR FILLET AND LAP WELDING
Arc Approx.
Metal Electrode Arc Argon Travel Electrode
Thickness(1) DC (EP)(4) Voltage(4) Consump.(3)
Weld Weld Diameter Gas Flow Speed
Position(2) Passes(3)
(In.) (In.) (Amps) (Volts) (cfh) (ipm/pass) (lb/100 ft.)
3/32 F, V, H, O 1 .030 100-130 18-22 30 24-30 1.8
1/8 F 1 .030-3/64 125-150 20-24 30 24-30 2
V, H 1 .030 110-130 19-23 30 24-30 2
O 1 .030-3/64 115-140 20-24 40 24-30 2
3/16 F 1 3/64 180-210 22-26 30 24-30 4.5
V, H 1 .030-3/64 130-175 21-25 35 24-30 4.5
O 1 .030-3/64 130-190 22-26 45 24-30 4.5
1/4 F 1 3/64-1/16 170-240 24-28 40 24-30 7
V, H 1 3/64 170-210 23-27 45 24-30 7
O 1 3/64-1/16 190-220 24-28 60 24-30 7
3/8 F 1 1/16 240-300 26-29 50 18-25 17
H,V 3 1/16 190-240 24-27 60 24-30 17
O 3 1/16 200-240 25-28 85 24-30 17
3/4 F 4 3/32 360-380 26-30 60 18-25 66
H, V 4-6 1/16 260-310 25-20 70 24-30 66
O 10 1/16 275-310 25-29 85 24-30 66
(1) Metal thickness of 3/4� or greater for fillet welds sometimes employs a double vee bevel of 50° or greater included vee with 3/32 to 1/8� land
thickness on the abutting member.
(2) F - Flat, V = Vertical, H = Horizontal, O = Overhead.
(3) Number of weld passes and electrode consumption given for weld on one side only.
(4) For 5XXX series electrodes use a welding current in the high side of the range and an arc voltage in the lower portion of the
range. 1XXX, 2XXX and 4XXX series electrodes would use the lower currents and higher arc voltages.
-16-
V. PULSING AND WAVEFORM MANIPULATION
depending on the wire diameter. This restricted aluminum
EVOLUTION OF POWER SUPPLIES FOR GAS
GMAW to relatively high heat input and, therefore, to
METAL ARC WELDING OF ALUMNINUM
relatively thick material [approximately 1/8� (3.2mm)
Early power supplies for GMAW were designed to hold
minimum thickness].
a steady arc length as wire was fed through the torch
This barrier was overcome with the advent of pulsed
and into the weld pool. It was found that the best way
GMAW. In this process, the current is rapidly pulsed
to do this was to set the internal volt/ampere curve of
between a relatively low background current and a high
the power supply so that, once the arc voltage was
peak current at severl hundred Hertz. The premise is
selected, the power supply would hold it steady. If the
that the peak current is high enough to get spray trans-
welder inadvertently pulled away from the weld, which
fer and we transfer metal across the arc in spray trans-
would increase the arc voltage, the power supply would
fer while the arc is at this current level. No metal is
allow the current to fall rapidly so that less wire was
transferred across the arc during the periods of back-
burned off and the arc voltage remained the same. If the
ground current. However, the average current, and
welder inadvertently tried to shorten the arc length, the
average heat input can now be significantly lower than if
power suppply increased the current to keep the arc
we don’t pulse the current. This has made it possible to
length constant. In this way, wire burnbacks and/or
routinely GMAW aluminum of thicknesses as low as
birdnests were minimized. This type of power supply
0.030� (0.7mm).
was called a constant voltage (CV) or constant potential
(CP) power supply.
Now that pulsed GMAW has become widespread,
Lincoln has taken the next step: the ability to tailor the
This type of power supply was and is still widely used.
details of the weld pulse to optimize the welding
However, when people started to fabricate aluminum in
process for certain specific characteristics.
heavy sections, a number of disadvantages were found
using CV power supplies for GMAW. These power
Today, Lincoln’s software controlled power sources like
supplies permitted very large fluctuations in current.
the PowerWaveâ„? 455 have become more sophisticated
Because of its high thermal conductivity, these fluctua-
and enable the user to manipulate the output
tions can result in cold lap weld defects in aluminum.
Waveform. Application specific software, like the
WaveDesigner Proâ„?, has been developed to optimize
Because of this, for many years it was strongly recom-
the arc characteristics. A modified constant current
mended that all aluminum GMAW be performed with
output is normally employed as a high frequency pulse
constant current (CC) or “drooping� power supplies
that is one of the main benefits of constant current. This
such as those normally used for SMAW and GTAW.
major benefit is the high-energy heat input during the
When this type of power suuply was used, current
peak, which produces the required penetration.
fluctuations were minimized. The action of the power
Advantages obtained by pulsing include reduced spat-
supply still tended to let the arc voltage self-adjust,
ter levels, improved puddle fluidity with an increase in
although not as quickly as if CV power supplies were
effective travel speeds, and reduced heat input with
used.
lower distortion levels. It may seem like a contradiction
However, the situation changed somewhat with the
in terms to say that high-energy heat input is obtained
introduction of inverter, and especially, software controlled
yet heat input and distortion is less. The reason this is
inverter, power supplies. Wide current fluctuations were
possible is a more effective use of the total heat gener-
no longer encountered and the arc of CV inverter power
ated by the arc. The general term heat input does not
supplies was more stable. Because of this, CV inverter
consider the efficiency of the heat transferred to the
type power supplies are generally acceptable for
base material and weld.
GMAW of aluminum alloys and have come into more
general use for welding aluminum. Drooper power sup-
plies still appear to have advantages when welding with
larger diameter wires [3/32� (2.4mm) or greater] on
heavy sections, 1/2� (12.7mm) thickness or greater.
GMAW for aluminum still suffered from one big
disadvantage even with the advent of inverter power
supplies. Unlike steel, short circuiting arc transfer is not
recommended for welding aluminum because short arc
welds in aluminum are prone to fine line lack of fusion
defects. Therefore, GMAW of aluminum alloys was
always recommended to be performed in spray transfer
mode. In order to get spray transfer, we needed a
certain minimum, but relatively high, transition current,
-17-
ANATOMY 0F A WAVEFORM PROCESS OPTIMIZATION VIA MANIPULATING
WAVEFORM
What exactly is the waveform control technology provid-
ed by Wave Designer Pro? With this technology, the Manipulating the waveform can have a predictable
power source responds to changes demanded by the effect on travel speeds, final weld bead appearnce,
software instantaneously. Current is raised to a level postweld cleanup and welding fume levels. The real
higher than the transition current for spray transfer for a beauty in the manipulation of the waveform in Wave
few milliseconds. During this time, the molten droplet is Designer Pro, is how easy it is to creat a visual apper-
formed, detached, and it begins its excursion across ance of the waveform. The user can then make
the arc. Additional energy can now be applied to the changes while the arc is running, real time changes, or
molten droplet during its descent that allows it to main- the arc can be viewed on a five channel ArcScopeâ„?
tain its fluidity or increase its fluidity. The pulse is now where current peaks. voltage peaks, power and heat
moving to a low background current that sustains the input calculations can be instantaneously viewed. The
arc to cool the cycle, but it prepares for the advance- ArcScope samples data at a rate of 10KHz and is a
ment to the next pulse peak. Keep in mind that the valuable, optional-addition to the WaveDesigner soft-
“waveform� is the means for determing the performance ware. The ArcScope gives the engineer a visual compi-
characteristics of a single molten droplet of electrode. lation of the created waveform. Critiques can be made
The area under the waveform determines the amount of and adjustments can then be made to further optimize
energy applied to that single droplet. the waveform.
Lets look at the waveform in detail. In Figure 9, the front On thin [.035� (0.8mm)], aluminum base materials, we
flank (A) is the rise to peak, measured in amps per can reduce heat input, reduce distortion, eliminate spat-
millisecond, where the molten droplet is formed at the ter, cold lap and burn-throughs with the use of wave-
end of the electrode. As the molten droplet reaches form technology. This has been done repeatedly in
peak it detaches. A percent of current “overshoot�, (B), applications that can benefit from pulsed GMAW.
provides arc stiffness and it assists with the detachment Welding programs can be created that will apply to a
of the molten droplet from the end of the electrode. The very specific range of wire feed speeds and/or cur-
time spent at peak, (C) determines the droplet size; low rents or they can be created to follow a very wide range
times result in small droplets and longer times result in of material thicknesses with a broad range of wire feed
larger droplets. From there the detached molten droplet speed.
is affected by energy supplied by the rear flank. The rear
flank is comprised of tailout, (D), and stepoff, (E). Tailout FIGURE 9
can add energy to the molten droplet if it is increased. It
can assist with puddle fluidity especially when the tailout
speed is decreased. Stepoff is the place where tailout
ends but it has impact on the stability of the anode and
manipulation of the height of the pulse peak and result
in the elimination of fine droplet overspray. From this
point the waveform moves to the background current ,
(F), where the arc is sustained. The time at the back-
ground current as it decreases has the effect of increas-
ing the pulse frequency. The higher the pulse frequency
the higher the average current will become. Higher and
higher frequencies will result in a more focused arc.
Superimposed, in a selective fashion, over the wave-
form is the “adaptive� characteristic of synergic pulse
GMAW. Adaptive, or adaptivity, refers to the ability of
the arc to maintain a specific length despite changes in
electrical stickout. This is an important enhancement for
weld bead consistency and sound weld metal.
-18-
VI. TROUBLESHOOTING GUIDE
PROBLEM CAUSE POSSIBLE CURE
Porosity Turbulence of weld pool Shorten contact tip to work distance.
Moisture from environment
Hydrogen contamination Keep wire dry and covered. Clean base
of materials. metal prior to welding.
Contaminated shielding gas Keep dew point below -70°F (-57°C) increase
or inadequate flow flow rate, shield from air disturbance, too small
gas nozzle.
Fast cooling rate weld pool Use higher welding current and/or slower
speed. Preheat base metal. In vertical welding,
wrong progression � weld vertical up.
Weld Cracking Improper choice of filler metal Select filler metal with lower melting and
solidification temperatures.
Critical chemistry range Avoid weld pool chemistry of 0.5-2.0% Si and
1.0-3.0% Mg. Avoid Mg2Si eutectic problems
(5XXX welded with 4XXX).
Inadequate edge preparation Reduce base metal dilution of weld through
or spacing increased bevel angle and spacing.
Incorrect weld technique Clamp to minimize stress. Narrow heat zone by
increasing traverse speed. Produce convex
versus concave bead. Minimize super-heated
molten metal to control grain size.
No filler metal Add filler metal in GTAW of heat-treatable
alloys.
Burnback Insufficient wire feed Increase wire feed (CC), or reduce arc voltage
Irregular wire feed (CV).
Electrode kinked Replace.
Flexible conduit too long Replace.
Worn or dirty liner Replace.
Worn or dirty contact tip Replace.
Arcing in contact tube Match contact tube size to wire.
Over-heating of the gun Reduce duty cycle, use water-cooled gun.
Wrong polarity Change polarity.
Poor Arc Starting Improper grounding Reconnect ground.
No shielding gas Pre-purge gas shielding.
Wrong polarity Change polarity.
Dirty Welds Inadequate gas coverage Increase gas flow. Clean spatter from nozzle.
Hold gas nozzle closer to work. Replace
damaged gas nozzle. Center contact tube in
gas nozzle. Decrease gun angle. Check for
leaks.
Dirty electrodes Keep electrodes covered.
Dirty parent material Clean, degrease parent material.
Oxide film or water on parent Clean joint area.
-19-
PROBLEM CAUSE POSSIBLE CURE
Unstable Arc Poor electrical connections Check electrical connections.
Dirt in joint area Clean, degrease joint area.
Arc blow Do not weld in area of strong magnetic field.
Weld Bead Excessively Welding current too high, Modify welding parameters.
Wide travel speed too low, and/or
arc length too long.
Inadequate Penetration, Insufficient welding current Increase current.
Incomplete Fusion Travel speed too high Reduce travel speed.
Arc length too long Decrease arc length.
Dirty parent material Clean, degrease joint area.
Inadequate joint spacing or Redesign joint.
edge preparation
Oxide on base material or wire Clean.
Insufficient depth or improper Increase depth of back-gouge (U- or V- type).
shape of the back-gouge.
Mismatch of Color After Improper alloy selection Match color selection. Avoid 4XXX filler wires,
Anodizing use 5XXX filer wires with 5XXX and 6XXX base
alloys.
VII. REFERENCES
Welding Kaiser Aluminum, Second Edition, Kaiser Aluminum & Chemical Sales, Inc., Oakland, CA 94643.
Welding Handbook, Volume 3, Materials and Applications, Eight Edition, AWS, 1996.
Welding Aluminum: Theory and Practice, The Aluminum Association, Third Edition, November 1997.
Registration Record of Aluminum Association Designations and Chemical Composition Limits for Wrought
Aluminum and Wrought Aluminum Alloys, The Aluminum Association, Washington, DC.
Specification for Bare Aluminum and Aluminum Alloy welding Electrodes and Rods, ANSI/AWS A5.10.
-20-
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1� from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety� booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
Mar �95
-21-
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
� DC Manual (Stick) Welder. your head out of the fume. Use enough
� AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot�. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying operations.
welding machine in good, safe operating condition. Replace
The heat and rays of the arc can react with solvent vapors to
damaged insulation.
form phosgene, a highly toxic gas, and other irritating
products.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically “hot� parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar �95
-22-
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact can
any other source of heat, sparks, or flame.
cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
-23-
iv iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions
prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes:
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
a. Les circuits à l’électrode et à la piéce sont sous tension
la masse sur la charpente de la construction ou d’autres
quand la machine à souder est en marche. Eviter toujours
endroits éloignés de la zone de travail, on augmente le risque
tout contact entre les parties sous tension et la peau nue
de voir passer le courant de soudage par les chaines de lev-
ou les vétements mouillés. Porter des gants secs et sans
age, câbles de grue, ou autres circuits. Cela peut provoquer
trous pour isoler les mains.
des risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on
câbles jusqu’� ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande
Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse.
galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble
produit des fumeés toxiques.
de soudage et la machine à souder en bon et sûr état
defonctionnement.
10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le
d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir.
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension
du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à souder
ou autres produits irritants.
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
f. Si on utilise la machine à souder comme une source de
le code “Code for safety in welding and cutting� CSA Standard
courant pour soudage semi-automatique, ces precautions
W 117.2-1974.
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
PRÉCAUTIONS DE SÛRETÉ POUR
enrouler le câble-électrode autour de n’importe quelle partie
LES MACHINES À SOUDER À
du corps.
TRANSFORMATEUR ET À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
REDRESSEUR
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray- 1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc. de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. �93
-24-
-25-
-26-
Customer Assistance Policy
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment.
Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for
advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time.
Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information of advice. We
expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such informa-
tion or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or
advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our
products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of,
and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying
this type of fabrication methods and service requirements.
-27-
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