aluminium mig welding guide.pdf

8/10/2019 Aluminium Mig Welding Guide.pdf

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SUPERGLAZE ALUMINUM WIRE TECHNICAL GUIDE

CONTENTS

I. THE EXTRAORDINARY ADVANTAGES OF SUPERGLAZE . . . . . . . . . . . . . . . . . . . . . . . . .3

II. EFFECTS OF ALLOYING ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Metallurgy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Alloying Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5Temper 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12Causes 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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SuperGlaze Available

Alloys Diameters

1100.030 (0.8mm)

4043.035 (0.9mm)

4047.040 (1.0mm)

51833/64” (1.2mm)

53561/16” (1.6mm)

55543/32” (2.4mm)

5556

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I. THE EXTRAORDINARY ADVANTAGESOF SUPERGLAZE

CONTROLLING ALLOYS

The process of making aluminum MIG wires is a complex

one, but one in which Lincoln has a clear and distinct

advantage. We are the only manufacturer that melts the

raw materials to make MIG wire. First, we utilize auto-

mated tilting furnaces to efficiently produce the properaluminum 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,

hydrogen alkaline metals, and inclusions. Consistent

chemical composition produces superior arc stability.

CONTINUOUS CASTING

Second, we use a continuous casting process specially

configured for high alloy materials. This process keeps

the surface free from imperfections and impurities.

Minimal surface contaminants reduces risk of porosity in

welds.

DRAWING THE WIRE

In the last step of the process, we use advanced wire

drawing technology to preserve both surface integrity

and internal soundness. This is also the step where our

proprietary process, SuperGlaze, is used for unmatched

product quality. It is also the only MIG wire on the

market that is shaved twice! This smooth surface finish

gives superior feedability.

5356 Wire SurfaceMagnified 60x

SuperGlaze

“Best in Class”

Typical Competitive

Product

Standard SuperGlaze Products



II. EFFECTS OF ALLOYING ELEMENTS

METALLURGY

To understand aluminum, we must first understand

some basics about aluminum metallurgy. Aluminum can

be alloyed with a number of different elements, both

primary and secondary, to provide improved strength,

corrosion resistance and/or general weldability.

The primary elements that alloy with aluminum are

copper, silicon, manganese, magnesium and zinc. It isimportant to note that these alloys fall into two classes:

heat-treatable or nonheat-treatable.

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.

The next step in the process is to maintain it at a lower

temperature long enough to allow a controlled amount

of precipitation of the alloying elements.

With the nonheat-treatable alloys it is possible toincrease strength only through cold working or strain

hardening. To do this, a mechanical deformation must

occur in the metal structure, resulting in increased

resistance to strain, producing higher strength and

lower ductility.

Two designations have been developed to identify

aluminum alloys. The most commonly used alloys are

normally identified using wrought alloy designations.

This designation is a four digit number where the first

digit indicates the principal alloying element or elements.

If the second digit is not zero, then the original registered

alloy has been modified in some way. The third and

fourth digits are arbitrary numbers that identify the

specific alloy, as shown in Table 1 on page 6. The

exception to this is with the 1XXX series alloys that are

almost pure aluminum. For this series, these digits

indicate the degree of purity above 99.00%. For

example, 1080 is 99.80% pure aluminum.

For cast alloy designations, a three digit number plus

one decimal is used to designate each cast alloy. The

first digit indicates the principal alloying element. The

cast alloy designations lack the modification digit of the

wrought designations. Instead modifications are indicat-

ed by a prefix letter (A,B,C, etc.). The second and third

digits form the arbitrary number identifying the specific

alloy. The decimal indicates whether the alloy composi-

tion is for the final casting (.0), or for the ingot (.1 or .2

depending on purity limits).

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Wrought Aluminum Alloys:

Aluminum

Al Cu Mn Si Mg Mg/Si Zn Other

1XXX 2XXX 3XXX 4XXX 5XXX 6XXX 7XXX 8XXX

NonHeat-Treatable Heat-Treatable

Cast Aluminum Alloys:

Aluminum

Si+Cu Al Cu and/or Mg Si Mg Zn Sn Other

1XX.X 2XX.X 3XX.X 4XX.X 5XX.X 7XX.X 8XX.X 9XX.X

NonHeat-Treatable Heat-Treatable

ALLOYING ELEMENTS

Pure Aluminum (1XXX series) Contains no alloying

elements, and is considered nonheat-treatable. It is

used primarily in chemical tanks and pipe because of its

superior corrosion resistance. This series is also used in

electrical bus conductors because of its excellent elec-

trical conductivity. Easily welded with 1100 and 4043

filler wires.

Copper (2XXX series) Provides high strength to

aluminum. This series is heat-treatable and mainly used

in aircraft parts, rivets and screw products. Most 2XXX

series alloys are considered poor for arc welding

because of their sensitivity to hot cracking. These alloys

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

welded with 4043 or 2319 filler wire. These alloys are

widely used in welded fabrication.

Manganese (3XXX series) Yields a nonheat-treatableseries used for general-purpose fabrication and build-

up. Moderate in strength, the 3XXX series is used for

forming applications including utility and van trailer

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

cracking. Its moderate strengths do prevent this series

from being used in structural applications.



Silicon (4XXX series) Silicon reduces the melting point

of the aluminum and improves fluidity. Its principle use is

as filler metal. The 4XXX series has good weldability and

is considered a nonheat-treatable alloy. Alloy 4047 is

becoming the alloy of choice in the automotive industry

as it is very fluid and good for brazing and welding.

Magnesium (5XXX series) When added to aluminum,

magnesium has excellent weldability with a minimal loss

of strength and is basically not prone to hot cracking. Infact, the 5XXX series has the highest strength of the

nonheat-treatable aluminum alloys. It is used for chemi-

cal storage tanks and pressure vessels at elevated

temperatures as well as structural applications, railway

cars, dump trucks and bridges because of its corrosion

resistance.

Silicon and Magnesium (6XXX series) This medium

strength, heat-treatable series, is primarily used in auto-

motive, pipe, railings, and structural and extruding

applications. The 6XXX series is somewhat prone to hot

cracking, but this problem can be overcome by the

correct choice of joint and filler metal. Can be weldedwith either 5XXX or 4XXX series without cracking —

adequate dilution of the base alloys with selected filler

wire is essential. A 4043 filler wire is the most common

for use with this series.

Zinc (7XXX series) Zinc added to aluminum with mag-

nesium and copper produces the highest strength heat-

treatable aluminum alloy. It is primarily used in the air-

craft industry. The weldability of the 7XXX series is com-

promised in higher copper grades, as many of these

grades are crack sensitive (due to wide melting ranges

and low solidus melting temperatures). Grades 7005

and 7039 are weldable with 5XXX filler wires. They arewidely used for bicycle frames and other extruded appli-

cations.

Other (8XXX Series) Other elements that are alloyed

with aluminum (i.e. lithium) all fall under this series. Most

of these alloys are not commonly welded, though they

offer very good rigidity and are principally used in the

aerospace industry. Filler wire selection for these heat-

treatable alloys include the 4XXX series.

In addition to the primary aluminum alloying elements,

there are a number of secondary elements, which

include chromium, iron, zirconium, vanadium, bismuth,

nickel and titanium. These elements combine with alu-

minum to provide improved corosion resistance,

increased strength and better heat treatability.

TEMPER DESIGNATIONS

(In general, not relevant for ordering filler wires)

The Aluminum Association Temper Designation System

is used for all forms of wrought and cast aluminum and

aluminum alloys except ingots. Some aluminum alloys

achieve temper by strain hardening and some by heat

treatment. In general the 1XXX, 3XXX, 4XXX and 5XXX

series wrought alloys are strain hardenable. The 2XXX,

6XXX and 7XXX series wrought alloys are heat-treatable.

The 2XX.X, 3XX.X, 4XX.X and 7XX.X series cast alloys

are heat-treatable. Strain hardening is not generally

applied to castings.

Basic temper designations are:

“F” As fabricated.

“O” Annealed. For lower strength condition, improved

ductility and dimensional stability.

“H” Strain-hardened. Applies to wrought products

which are strengthened by stain-hardening

through cold-working.

“W” Solution heat-treated. An unstable temperapplicable only to alloys which age spontaneously

at room temperature after solution heat-treatment.

Solution heat-treatment involves heat treating the

alloy to 1000°F (538°C) to bring the alloying ele-

ments into solid solution, followed by rapid

quenching to achieve a super saturated solution

at room temperature.

“T” Thermally treated to produce stable tempers

other than “F”, “O” or “H”.

T1 Naturally aged

T2 Cold worked and naturally aged

T3 Solution heat treated, cold worked and

naturally aged

T4 Solution heat treated and naturally aged

T5 Artificially aged

T6 Solution heat treated and artificially aged

T7 Solution heat treated and stabilized

T8 Solution heat treated, cold worked and

artificially aged

T9 Solution heat treated, artificially aged and

cold worked

T10 Cold worked and artificially aged

An example of a complete designation is: 2014-T6. This

means that it is alloyed with copper (2XXX series) and

the T6 refers to the fact that it is solution heat-treatedand artificially aged.

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Lincoln Electric SuperGlaze Aluminum alloy wires are

manufactured to meet requirements as specified in

AWS/ANSI A5.10 Specification of Bare Aluminum Alloy

Welding Electrodes. All SuperGlaze Aluminum alloy

wires are intended for GMAW (Gas Metal Arc Welding) .

with Argon or Helium/Argon gas mixtures.

Table 1 shows the chemical composition of standard

and special SuperGlaze MIG wires that are available.

AWS A5.10-92

ASME SFA-5.10

ClassificationMn Si Fe Mg Cr Cu Ti Zn Be Others(g) Al

ER1100 & 0.05 (b) (b) — — 0.05-0.20 — 0.10 0.05 99.0

Alloy 1050(a)(h)

ER2319(a) 0.20-0.40 0.20 0.30 0.02 — 5.8-6.8 0.10-0.20 0.10 (d) 0.05(e) rest

ER4043 0.05 4.5-6.0 0.8 0.05 — 0.30 0.20 0.10 (d) 0.05 rest

ER4047 0.15 11.0-13.0 0.8 0.10 — 0.30 — 0.20 (d) 0.05 rest

ER4643(a) 0.05 3.6-4.6 0.8 0.10-0.30 — 0.10 0.15 0.10 (d) 0.05 rest

Alloy 5052(a)(h) 0.10 0.25 0.40 2.2-2.8 0.15-0.35 0.10 — 0.10 (d) 0.05 rest

Alloy 5056(a)(h) 0.05-0.20 0.30 0.40 4.5-5.6 0.05-0.20 0.10 — 0.10 (d) 0.05 rest

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 (d) 0.10-0.20 rest

Alloy 5154(a)(h) 0.10 0.25 0.40 3.1-3.9 0.15-0.35 0.10 0.20 0.20 (d) 0.05 rest

ER5183 0.50-1.0 0.40 0.40 4.3-5.2 0.05-0.25 0.10 0.15 0.25 (d) 0.05 rest

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 (d) 0.05 rest

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 (d) 0.05 rest

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 (d) 0.05 rest

ER5654(a) 0.01 (c) (c) 3.1-3.9 0.15-0.35 0.05 0.05-0.15 0.20 (d) 0.05 rest

Alloy 5754(a)(h) (f) 0.25 0.40 2.6-3.6 0.05-0.30 0.05 0.15 0.20 (d) 0.05 rest

TABLE 1WIRE CHEMICAL COMPOSITION (%)

(Single Values are Maximum, except of Aluminum)

(a) SuperGlaze alloy available on a made-to-order basis.

(b) Silicon + Iron shall not exceed 0.95%.

(c) Silicon + Iron shall not exceed 0.45%.

(d) Beryllium shall not exceed 0.0008%.

(e) Vanadium content shall be 0.05 - 0.15% and

Zirconium content shall be 0.10 - 0.25%.

-6-

(f) Mn + Cr = 0.10 - 0.60% (minimum Mn of 0.20% or

minimum Cr of 0.1%).

(g) Total “others” shall not exceed 0.15%.

(h) Not included in AWS A5.10, ASME SFA-5.10.

CHEMICAL COMPOSITION OF SUPERGLAZE

MIG WIRES



ELECTRODE DESCRIPTION AND SELECTION

ER1100 The 1XXX series of filler alloys make the soft-

est electrode wire and require extra care to ensure good

feeding. Electrical and chemical applications for aluminum

often use base metal with little or no alloying elements

and filler alloys for these are often required to have simi-

lar compositions. ER1100 is suitable in most cases

although it contains a small amount of Cu.

ER2319 This alloy is designed to weld the 2XXX alloys2219 and 2519. While these alloys can also be welded

with ER4043, ER2319 gives significantly higher welded

properties.

ER4043, ER4047 ER4043 was developed for the

welding of heat-treatable base alloys and more specifi-

cally the 6XXX series alloys. It has a lower melting point

and more fluidity than the 5XXX series filler alloys, and is

preferred by most welders because of its operating

characteristics and is less sensitive to weld cracking

with the 6XXX series base alloys. These alloys are not

suitable for welding Al-Mg alloys (specifically alloys

5083, 5086, 5456) because excessive magnesium-sili-

cide (Mg2Si) may develop in the weld structure to

decrease ductility and increase crack sensitivity.

ER4047 was developed as a brazing filler metal to take

advantage of its much lower melting point and higher

fluidity, but it is used as a welding filler alloy also.

ER4047 can be used as a substitute for ER4043 to pro-

vide increased Si in the weld metal to minimize hot

cracking and to produce higher fillet weld shear

strengths. All 4XXX series filler alloys are suitable for

sustained elevated temperature service, i.e. above

150°F (65°C).

ER4643 This alloy is designed for one purpose only.

There is enough magnesium added to this alloy so that itwill respond to heat treatment. It is designed for use on

weldments which will be completely re-heat treated (ie,

solution heat treated, quenched and aged) after welding

and will provide the highest joint strength of any of the

filler metals under these circumstances.

ER5356, ER5183, ER5554, ER5556, ER5087 These

alloys are designed for the welding of 5XXX series base

alloys to themselves and other alloys. Because of their

higher hardness and strength, the feedability of the

5XXX filler alloys in GMAW is significantly better than

that of ER4043 or ER4047.

ER5356 is the most commonly used 5XXX filler alloy. Itis suitable for welding any of the 5XXX base materials.

However, when welding some of the stronger 5XXX

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

amounts of magnesium, manganese, and/or zirconium,

are capable of meeting minimum required welded ten-

sile stresses for the higher strength 5XXX alloys.

ER5356, ER5556 and ER5183 and are also suitable for

welding the 5XXX aloys to 6XXX and weldable 7XXX

alloys. However, since these alloys contain magnesium

levels above 3%, they are not suitable for use in appli-

cations where the service temperature exceeds 150°F

(65°C). Prolonged exposure above 150°F (65°C) will

sensitize these alloys to stress corrosion cracking andresult in premature failure. For the same reason, post

weld stress relieving or post weld aging operations

should not be performed when these filler alloys are used.

ER5554 is intended as a matching filler alloy when

welding 5454 base materials. This alloy is a lower

magnesium content alloy and is often used for auto-

motive wheels, over the road trailers, and rail tank cars

where the weld filler metal chemistry must closely match

the base material chemistry to maximize corrosion

performance.

FILLER ALLOY SELECTION

Selection of the most suitable filler alloy for each weld-

ing application could be simple when structures are to

be built of the common alloys using common fabrication

practices and when they are to be exposed to common

service conditions. However, special service conditions

and/or special base alloys may require special filler

alloys. The following metal selection methodology

should be followed:

1. Determine base metals and thicknesses.

2. Determine process and joint geometry.

3. Determine requirements:

Cracking resistance,

Weld metal strength and ductility.

Corrosion resistance,

Weld performance at elevated temperatures,

Weld metal fluidity.

Weld metal color match.

4. For “nonheat-treatable alloys”: use filler selection

charts with attention to requirements. Note that

Medium Mg 5XXX materials such as 5052 can be

sensitive to hot cracking. Dilution may need to be

considered where strength is important.

For “heat-treatable alloys”: Dilution, hot cracking,

HAZ cracking, ductility and heat treatment after

welding needs to be considered in addition torequirements.

The Filler Metal Guide, Table 2 on page 8, covers both

wrought and cast alloys.

-7-



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

10601070 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 j1350

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 5183c,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

5456 5356 5356 5556 5356 5356 5556

c,e,i e e e e e

6061

6063

6101 4145 4043 5356 5356 4043 40436201 c,i f,i b,c b,c,i b,i b,i

6151

63516951

6070 4145 4043 5356 5356 4043

c,i f,i c,e c,e,i e,i

7005 k

7039

710.0 4043 4043 5356 5356

711.0 i b,i b e

712.0

511.0

512.0 4043 5654

513.0 b,i b,d

514.0

356.0

357.0

359.0 4145 4043

413.0 c,i d,i

444.0443.0

319.0

333.0

354.0 4145

355.0 d,c,i

380.0

TABLE 2 - FILLER METAL GUIDE

ADDITIONAL GUIDELINES

1. Service conditions such as immersion in fresh or salt water,

exposure to specific chemicals, or exposure sustained hightemperature (over 150°F) may limit the choice of filler metals.

Filler alloys 5356, 5183, 5556 and 5654 are not recommended

for sustained elevated temperature service.

2. Guide lines in this table apply to gas shielded arc welding

processes.

3. Where no filler metal is listed, the base metal combination is

not recommended for welding.

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 theresults obtained in applying this type of information. These variables include, but are not limited to, weldingprocedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements.

-8-

Notes: All filler materials are listed in AWS specification A5.10.

a. Base metal alloys 5652 and 5254 are used for hydrogen

peroxide service, 5654 filler metal is used for welding both

alloys for low temperature [150°F (65°C)] service.

b. 5183, 5356, 5454, 5556 and 5654 may be used. In some

cases they provide improved color match after anodizing,

highest weld ductility and higher weld strength. 5554 is

suitable for elevated temperature service.

c. 4043 may be used for some applications.

d. Filler metal with the same analysis as the base metal is

sometimes used.

e. 5183, 5356 or 5556 may be used.

f. 4145 may be used for some applications.

g. 2319 may be used for some applications.

i. 4047 may be used for some applications.

j. 1100 may be used for some applications.

k. This refers to 7005 extrusions only.



HOW ALLOYS EFFECT MECHANICAL PROPERTIES

The weld deposit is a mixture of the filler metal and base

metal. Strength, ductility, resistance to weld cracking,

corrosion resistance, heat-treatability and other proper-

ties may be influenced by the amount of dilution of the

weld metal by the base metal. Dilution is a function of

joint design, welding process and welding procedure.

Weld cracking tendencies are generally reduced by

keeping base alloy dilution of the weld metal to a

minimum. Edge prepared joints reduce dilution of theweld by base metal and thus reduce the possibility of

hot cracking. In general, preheating should be avoided,

multiple passes are preferred over fewer passes, and

welding speeds should be as high as practical.

Typical mechanical properties of gas shielded arc

welded butt joints in nonheat-treatable and heat-treatable

alloys are listed in Table 3 on page 10.

In examining Table 3, it is clear that the welded

strengths of most aluminum alloys are lower than the

tensile strength of the starting material. In general, it is

not possible when welding aluminum alloys, to produce

welds as strong as the parent material. In order to

understand why this is so, some of the metallurgy of

heat-treatable and nonheat-treatable aluminum alloys

must be discussed.

The nonheat-treatable alloys, (1XXX, 3XXX, 4XXX and

5XXX), are not hardenable by heat treatment. They

come off the hot mill, are annealed in a large furnace to

obtain the “O” temper condition, and then are cold

rolled (or otherwise cold worked) to strengthen them. If

they are welded, the heat of welding acts as a local

annealing treatment for the heat affected zone (HAZ).

The mechanical properties in the HAZ are those of the

annealed (ie “O” temper) material. It makes no difference

what temper the material is in before welding. After

welding, the properties are those of the “O” temper.

Therefore, although welds in “O” temper materials will

be as strong as the starting material, welds in materials

in other tempers will be weaker, sometimes significantly,

than the starting material. There is no practical wayto

restore the strength lost during welding. There is no

heat treatment which will help.

The situation when using heat-treatable alloys, (2XXX,

6XXX and 7XXX), is somewhat more complex. These

alloys are heat treated at the mill by holding at approxi-

mately 1000°F (538°C) for a short time. This is called asolution heat treatment. The alloy is then quenched,

usually in water. If the process is stopped at this point,

the material is said to be in the T4 (naturally aged)

temper. However, the material can be further increased

in strength by performing an aging heat treatment at

approximately 400°F (204°C) for one hour. At this point,

the material is said to be in the T6 temper. Most heat-

treatable alloys are sold in this temper.

When T4 or T6 materials are welded, the heat of weld-

ing affects the properties in the HAZ, reducing them.

Properties are usually not reduced all the way down to

the “O” temper. It is difficult to give a general rule

regarding the reduction in properties. The specific value

depends on the alloy and temper under consideration.

However, as an example, 6061-T6 is required to have a

minimum utlimate tensile strength of 40 ksi (276 MPa)

before welding. In the welded condition, most codes

require a minimum tensile stress of 24 ksi (165 MPa), sothat the reduction can be significant.

However, it is possible to restore the mechanical prop-

erties, at least in part, by heat treating after welding.

Alloys welded in the T6 temper will show a slight

improvement in strength if they are aged after welding at

approximately 400°F (204°C) for one hour. A much

larger improvement will be observed if the material is

welded in the T4 temper and aged at 400°F (204°C) for

one hour after welding. Finally, with the proper choice of

weld filler alloy, the welded assembly can be re-solution

aged, quenched, and aged to obtain the full T6 proper-

ties. This last course of action is clearly not always prac-

tical, especially for large structures, but may be practical

for smaller ones.

Almost all alloys, except 7XXX, of the common aluminum

alloys can be welded without impairing their corrosion

resistance. Also, in general the choice of welding

process does not influence corrosion resistance.

The excellent corrosion resistance of the 1XXX, 3XXX,

4XXX and 5XXX series nonheat-treatable alloys is generally

not affected by welding. Joints involving combinations

of these alloys also have good corrosion resistance. In

prolonged service at elevated temperatures [above

150°F (65°C)] of 5XXX series alloys containing morethan 3% magnesium however, these alloys eventually

become sensitive to stress corrosion. In this type of ser-

vice lower magnesium content alloys like 5454 should

be used.

The aluminum-magnesium-silicon heat-treatable alloys

such as 6061 and 6063 have generally good corrosion

resistance, unwelded or welded. However, immersed in

an electrolyte such as sea water, the HAZ may corrode

preferentially.

The 2XXX and 7XXX series heat-treatable alloys,

containing substantial amounts of copper and zinc and

some magnesium, may have corrosion resistancelowered by the heat of welding. Grain boundary

precipitation in the HAZ creates a difference in electrical

potential from the remainder of the weld metal and, if

there is an electrolyte present, selective corrosive attack

on the grain boundaries is likely to occur. Postweld

heat-treatment provides a more homogeneous structure

and improves the corrosion resistance of these alloys.

However, these are not the alloys of choice where

corrosion resistance is of primary importance.

-9-



-10-

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 585005 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 167005-T53 5556 44 303 25 172 10 33

TABLE 3

TYPICAL AS-WELDED MECHANICAL PROPERTIES OF GMAW WELDED BUTT JOINTS



CHART 2

WFS vs. AMPS

550

500

450

400

350

300

250

200

150

150 175 200 225 250

3/64” 5356

3/64” 4043

5356 4043 Amps WFS Amps WFS

150 325 150 270175 385 175 315200 440 200 360225 495 225 410250 545 250 460

-11-

WFS

(in./min)

AMPS

III. HOW PHYSICAL PROPERTIES EFFECT WELDING PROCEDURES

CHART 1

100

80

60

40

20

0

Copper 1100 4043 5356

Electrical Conductivity

(100%)

(59%)

(42%)

(29%)

ELECTRICAL CONDUCTIVITY

Physical properties of various aluminum alloys vary

more dramatically than with most other materials. One

of the most important differences is in their electrical

conductivity. For example, when compared to copper,

“pure” aluminum (ER1100) conducts electricity only

60% as well. When silicon and magnesium are added,

such as in ER4043 and ER5356, the conductivity can

drop to about 40% and 30% respectively versus copper.

This difference in conductivity has a significant effect on

welding procedures. As shown in chart 2, ideal

procedures for these two alloys have different wire feed

speed/amperage curves. In fact, when these 3/64”

(1.2mm) diameter wires are running at the same current

and voltage, the wire feed speed of the ER4043 alloy is

about 17% less. Therefore, if published procedures are

being used in developing or setting procedures, it is

important to know what alloy was used when they were

originally developed.

%



-12-

FIGURE 2

CTTWD VS. ARC LENGTH

Aluminum has a much higher electrical conductivity than

other materials. The longer stickout of an aluminum

wire, produces almost the same resistance in the weld-

ing circuit as a short stickout. This means that variations

in stickout have little effect on the arc and thus, the

weld. When the distance from the contact tip to work

distance (CTTWD) is increased as shown below, the arc

length remains about the same. This means that the

welding technique that operators may have learned to

cool off the arc, while welding ferrous materials, will not

be effective. However, in general, a short arc length is

required to produce good shielding gas coverage.

1/4"(6.4mm)

1/2"(12.7mm)

3/4"

(19.0mm)



-13-

FIGURE 3

EFFECT OF SHIELDING GAS

100% Argon

100% Helium

100% Argon

100% Helium

CAUSES OF AND CURES FOR WELD POROSITY

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

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

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.

Where does the hydrogen come from? There are two

primary sources; breakdown of hydrocarbons (ie, oils

and greases) in the arc and breakdown of water vapor

in the arc. In order to minimize porosity, good “house-

keeping” practices must be followed. These include:

• Preweld cleaning to remove oils and greases from the

base material.

• 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).

• Make sure the welding wire doesn’t have residual

drawing lubricant on its surface.

• Use a slight leading angle (10 to 15 Degrees), butdon’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

hotter, and the penetration profile to become wider, as

shown in Figure 3.

Additionally, the addition of helium to the argon shielding

gas can reduce porosity levels. Although the mechanism

for this phenomenon isn’t well understood, it can be

seen in Figures 4 and 5. Below are two broken fillet

welds made with the same SuperGlaze aluminum MIG

wire, same equipment, and same procedures. The only

difference was that the weld in Figure 4 was made using

pure argon gas and Figure 5 was made using 75% argon

/25% helium.

FIGURE 4

FIGURE 5



-14-

FIGURE 6

FIGURE 7

CLEANING BASE MATERIAL

The hydrated aluminum oxides or hydrocarbon contam-

ination on the surface of the base material is a problem

with aluminum alloys, more so with the 5XXX series

materials.

Wire brush, using stainless steel hand or power brushes

to remove hydrated aluminum oxides. These oxides

have a metling temperatures of 3720°F (2049°C), butthe base metal melts much lower at about 1200°F

(649°C). With the lower melting point, it is easier to start

an arc as well as get adequate penetration on clean

material. This oxide is also very abrasive and second in

hardness to diamonds. Aluminum oxides are used for

grinding wheels and sandpaper grit. This abrasion level

is terrible on liners and it is not electrically conductive as

well. Because of this, care should be taken to remove

surface oxides in the welding joint and where the work

is grounded.

Lubricants are sometimes used on the surface of

aluminum to form, draw and to protect its surface. These hydrocarbons contain hydrogen and they should

be removed prior to welding. Acetone can be used in

this case and it should be as effective in removing

surface oils.

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-

minum sheet and plate are given in Tables 4 and 5, on

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

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.

JOINT GEOMETRY

Typical joint geometrics for semiautomatic MIG welding

are shown in Figure 8 on page 15. Factors affecting the

choice of the joint geometry include metal thickness,

whether backing is to be used (and if so, what kind), the

welding position and whether welding is to be done

from one side of the joint, mostly from one side, or

about equally from both sides.

Where intermittent welding is to be used, only deviationfrom the regular pattern of torch travel is recommended.

GMAW (MIG) welding of aluminum normally leaves a

crater at the end of the weld, as illustrated in Figure 6

below. This crater is prone to cracking which, in turn,

could initiate fracture in the intermittent weld.

One method of avoiding this problem is to reverse the

direction of welding at the end of each tack or intermit-

tent weld, so that the crater is filled, as shown in Figure

7. Other techniques for eliminating cracking problems of

the crater area are:

1. Use run-on and run-off tabs.

2. Break the arc and restrike it to fill the crater.3. Use special circuitry and power source control to

produce a specific rate of arc decay.

IV. RECOMMENDED PROCEDURES

The finish of a MIG weld in aluminum leaves a crater that is very susceptible to cracking.

Doubling back at the end of a MIG weld eliminates thecrater and the cracking problems that usually accompany it.



FIGURE 8 - TYPICAL JOINT GEOMETRIES FOR SEMIAUTOMATIC ALUMINUM MIG WELDING.

-15-



TABLE 4 - TYPICAL SEMIAUTOMATIC ALUMINUM MIG PROCEDURES FOR GROOVE WELDING

TABLE 5 - TYPICAL SEMIAUTOMATIC ALUMINUM MIG PROCEDURES FOR FILLET AND LAP WELDING

Arc Approx.Metal Joint Electrode Arc Argon Travel Electrode

Thickness Weld Edge Spacing Weld Diameter DC (EP)(3) Voltage(3) Gas Flow Speed Consump.(In.) Position(1) Preparation(2) (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 1.5F 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 1.8F, 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 2F, 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 4F, V, H F 0-1/16 1 3/64 140-180 23-27 35 24-30 5O F 0-1/16 2F 3/64 140-175 23-27 60 24-30 5F, V H 3/32-3/16 2 3/64-1/16 140-185 23-27 35 24-30 8H, 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 6F 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 10O F 0-3/32 3F, 1R 3/64-1/16 180-200 25-29 60 25-35 10F, V H 1/8-1/4 2-3 3/64-1/16 175-225 25-29 40 24-30 12O, 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 16F 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 20O F 0-3/32 5F, 1R 1/16 200-250 26-29 80 25-40 20F, V H 1/4-3/8 4 1/16 210-290 26-29 50 24-30 35O, 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 50F 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 75F 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.

(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.

Arc Approx.Metal Electrode Arc Argon Travel Electrode

Thickness(1) Weld Weld Diameter DC (EP)(4) Voltage(4) Gas Flow Speed Consump.(3)

(In.) Position(2) Passes(3) (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 2O 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 4.5O 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 7O 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 17H,V 3 1/16 190-240 24-27 60 24-30 17O 3 1/16 200-240 25-28 85 24-30 17

3/4 F 4 3/32 360-380 26-30 60 18-25 66H, V 4-6 1/16 260-310 25-20 70 24-30 66O 10 1/16 275-310 25-29 85 24-30 66

-16-



V. PULSING AND WAVEFORM MANIPULATION

-17-

EVOLUTION OF POWER SUPPLIES FOR GASMETAL ARC WELDING OF ALUMNINUM

Early power supplies for GMAW were designed to hold

a steady arc length as wire was fed through the torch

and into the weld pool. It was found that the best way

to do this was to set the internal volt/ampere curve of

the power supply so that, once the arc voltage was

selected, the power supply would hold it steady. If thewelder inadvertently pulled away from the weld, which

would increase the arc voltage, the power supply would

allow the current to fall rapidly so that less wire was

burned off and the arc voltage remained the same. If the

welder inadvertently tried to shorten the arc length, the

power suppply increased the current to keep the arc

length constant. In this way, wire burnbacks and/or

birdnests were minimized. This type of power supply

was called a constant voltage (CV) or constant potential

(CP) power supply.

This type of power supply was and is still widely used.

However, when people started to fabricate aluminum inheavy sections, a number of disadvantages were found

using CV power supplies for GMAW. These power

supplies permitted very large fluctuations in current.

Because of its high thermal conductivity, these fluctua-

tions can result in cold lap weld defects in aluminum.

Because of this, for many years it was strongly recom-

mended that all aluminum GMAW be performed with

constant current (CC) or “drooping” power supplies

such as those normally used for SMAW and GTAW.

When this type of power suuply was used, current

fluctuations were minimized. The action of the power

supply still tended to let the arc voltage self-adjust,although not as quickly as if CV power supplies were

used.

However, the situation changed somewhat with the

introduction of inverter, and especially, software controlled

inverter, power supplies. Wide current fluctuations were

no longer encountered and the arc of CV inverter power

supplies was more stable. Because of this, CV inverter

type power supplies are generally acceptable for

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,

depending on the wire diameter. This restricted aluminum

GMAW to relatively high heat input and, therefore, to

relatively thick material [approximately 1/8” (3.2mm)

minimum thickness].

This barrier was overcome with the advent of pulsed

GMAW. In this process, the current is rapidly pulsed

between a relatively low background current and a high

peak current at severl hundred Hertz. The premise isthat the peak current is high enough to get spray trans-

fer and we transfer metal across the arc in spray trans-

fer while the arc is at this current level. No metal is

transferred across the arc during the periods of back-

ground current. However, the average current, and

average heat input can now be significantly lower than if

we don’t pulse the current. This has made it possible to

routinely GMAW aluminum of thicknesses as low as

0.030” (0.7mm).

Now that pulsed GMAW has become widespread,

Lincoln has taken the next step: the ability to tailor the

details of the weld pulse to optimize the weldingprocess for certain specific characteristics.

Today, Lincoln’s software controlled power sources like

the PowerWave™ 455 have become more sophisticated

and enable the user to manipulate the output

Waveform. Application specific software, like the

WaveDesigner Pro™, has been developed to optimize

the arc characteristics. A modified constant current

output is normally employed as a high frequency pulse

that is one of the main benefits of constant current. This

major benefit is the high-energy heat input during the

peak, which produces the required penetration.

Advantages obtained by pulsing include reduced spat-ter levels, improved puddle fluidity with an increase in

effective travel speeds, and reduced heat input with

lower distortion levels. It may seem like a contradiction

in terms to say that high-energy heat input is obtained

yet heat input and distortion is less. The reason this is

possible is a more effective use of the total heat gener-

ated by the arc. The general term heat input does not

consider the efficiency of the heat transferred to the

base material and weld.



-18-

ANATOMY 0F A WAVEFORM

What exactly is the waveform control technology provid-

ed by Wave Designer Pro? With this technology, the

power source responds to changes demanded by the

software instantaneously. Current is raised to a level

higher than the transition current for spray transfer for a

few milliseconds. During this time, the molten droplet is

formed, detached, and it begins its excursion across

the arc. Additional energy can now be applied to the

molten droplet during its descent that allows it to main-tain its fluidity or increase its fluidity. The pulse is now

moving to a low background current that sustains the

arc to cool the cycle, but it prepares for the advance-

ment to the next pulse peak. Keep in mind that the

“waveform” is the means for determing the performance

characteristics of a single molten droplet of electrode.

The area under the waveform determines the amount of

energy applied to that single droplet.

Lets look at the waveform in detail. In Figure 9, the front

flank (A) is the rise to peak, measured in amps per

millisecond, where the molten droplet is formed at the

end of the electrode. As the molten droplet reachespeak it detaches. A percent of current “overshoot”, (B),

provides arc stiffness and it assists with the detachment

of the molten droplet from the end of the electrode. The

time spent at peak, (C) determines the droplet size; low

times result in small droplets and longer times result in

larger droplets. From there the detached molten droplet

is affected by energy supplied by the rear flank. The rear

flank is comprised of tailout, (D), and stepoff, (E). Tailout

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 resultin 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 forweld bead consistency and sound weld metal.

PROCESS OPTIMIZATION VIA MANIPULATING

WAVEFORM

Manipulating the waveform can have a predictable

effect on travel speeds, final weld bead appearnce,

postweld cleanup and welding fume levels. The real

beauty in the manipulation of the waveform in Wave

Designer Pro, is how easy it is to creat a visual apper-

ance of the waveform. The user can then make

changes while the arc is running, real time changes, or

the arc can be viewed on a five channel ArcScope™where current peaks. voltage peaks, power and heat

input calculations can be instantaneously viewed. The

ArcScope samples data at a rate of 10KHz and is a

valuable, optional-addition to the WaveDesigner soft-

ware. The ArcScope gives the engineer a visual compi-

lation of the created waveform. Critiques can be made

and adjustments can then be made to further optimize

the waveform.

On thin [.035” (0.8mm)], aluminum base materials, we

can reduce heat input, reduce distortion, eliminate spat-

ter, cold lap and burn-throughs with the use of wave-

form technology. This has been done repeatedly inapplications that can benefit from pulsed GMAW.

Welding programs can be created that will apply to a

very specific range of wire feed speeds and/or cur-

rents or they can be created to follow a very wide range

of material thicknesses with a broad range of wire feed

speed.

FIGURE 9



VII. REFERENCESWelding 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.

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.

-20-



FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

____________________________________________________ 1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumesoutdoors.

____________________________________________________ 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 beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing and

tools away from V-belts, gears, fans and all other moving

parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requir ing their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________ 1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________ 1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap or

iSAFETYi

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 availablefrom 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.

WARNING

Mar ‘95

ELECTRIC ANDMAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causes

localized Electric and Magnetic Fields (EMF). Welding

current creates EMF fields around welding cables andwelding machines

2.b. EMF fields may interfere with some pacemakers, and

welders having a pacemaker should consult their physician

before welding.

2.c. Exposure to EMF fields in welding may have other health

effects which are now not known.

2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure

them with tape when possible.

2.d.2. Never coil the electrod e lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right

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.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

-21-



iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers from

the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK cankill.3.a. The electrode and work (or ground) circuits

are electrically “hot” when the welder is on.

Do not touch these “hot” parts with your bare

skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.

Make certain the insulation is large enough to cover your full

area of physical contact with work and ground.

In addition to the normal safety precautions, if welding

must be performed under electrically hazardous

conditions (in damp locations or while wearing wet

clothing; on metal structures such as floors, gratings or

scaffolds; when in cramped positions such as sitting,

kneeling or lying, if there is a high risk of unavoidable or

accidental contact with the workpiece or ground) use

the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomatic

welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical

connection with the metal being welded. The connection

should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical

(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and

welding machine in good, safe operating condition. Replace

damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of

electrode holders connected to two welders because voltage

between the two can be the total of the open circuit voltage

of both welders.

3.i. When working above floor level, use a safety belt to protect

yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing these

fumes and gases.When welding, keep

your head out of the fume. Use enough

ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special

ventilation such as stainless or hard facing (see

instructions on container or MSDS) or on lead or

cadmium plated steel and other metals or coatings

which produce highly toxic fumes, keep exposure as

low as possible and below Threshold Limit Values (TLV)

using local exhaust or mechanical ventilation. In

confined spaces or in some circumstances, outdoors, a

respirator may be required. Additional precautions are

also required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vapors

coming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors to

form phosgene, a highly toxic gas, and other irritating

products.

5.c. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,

especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the

material safety data sheet (MSDS) and follow your

employer’s safety practices. MSDS forms are available from

your welding distr ibutor or from the manufacturer.

5.e. Also see item 1.b.Mar ‘95

-22-



FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnect

switch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

iiiSAFETYiii

Mar ‘95

WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contact cancause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting of

Containers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

-23-



ivSAFETYiv

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructions

et les précautions de sûreté specifiques qui parraissent dans ce

manuel aussi bien que les précautions de sûreté générales suiv-

antes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours

tout contact entre les parties sous tension et la peau nue

ou les vétements mouillés. Porter des gants secs et sans

trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher

metallique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles une grande

partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état

defonctionnement.d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder

parce que la tension entre les deux pinces peut être le

total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions

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 jamaisenrouler le câble-électrode autour de n’importe quelle partie

du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,

donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray-

onnement de l’arc et des projections quand on soude ou

quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de

l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de

soudage. Se protéger avec des vêtements de protection libres

de l’huile, tels que les gants en cuir, chemise épaisse, pan-

talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de

la masse. Un court-circuit accidental peut provoquer un

échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on place

la masse sur la charpente de la construction ou d’autres

endroits éloignés de la zone de travail, on augmente le risque

de voir passer le courant de soudage par les chaines de lev-

age, câbles de grue, ou autres circuits. Cela peut provoquer

des risques d’incendie ou d’echauffement des chaines et des

câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particuliérement important pour le soudage de tôles

galvanisées plombées, ou cadmiées ou tout autre métal qui

produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant

d’opérations de dégraissage, nettoyage ou pistolage. La

chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs

du solvant pour produire du phosgéne (gas fortement toxique)

ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir

le code “Code for safety in welding and cutting” CSA Standard

W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de

l’électricité et aux recommendations du fabricant. Le dispositif

de montage ou la piece à souder doit être branché à une

bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront

effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch-

er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur

place.

Mar. ‘93

-24-



-25-



-26-



-27-

Customer Assistance Policy

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipmenOur challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric foradvice or information about their use of our products. We respond to our customers based on the best information in our possession at that timeLincoln Electric is not in a position to warrant or guarantee such advice, and assumes no l iability, with respect to such information of advice. Weexpressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information oadvice 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 ourproducts.

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 applyingthis type of fabrication methods and service requirements.



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Phone: (305) 888-3203

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Phone: 31 24 3522 911

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Phone: (216) 481-8100

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U.S.A.

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