SUPERGLAZE ALUMINUM MIG WELDING GUIDE

For GMAW Welding

SUPERGLAZE ALUMINUM WIRE TECHNICAL GUIDE CONTENTS

I. II. THE EXTRAORDINARY ADVANTAGES OF SUPERGLAZE . . . . . . . . . . . . . . . . . . . . . . . . .3 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 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 advantage. We are the only manufacturer that melts the raw materials to make MIG wire. First, we utilize automated 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, 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.

Typical Competitive Product

SuperGlaze Best in Class

5356 Wire Surface

Magnified 60x

Standard SuperGlaze Products

SuperGlaze Alloys 1100 4043 4047 5183 5356 5554 5556 Available Diameters .030 (0.8mm) .035 (0.9mm) .040 (1.0mm) 3/64 (1.2mm) 1/16 (1.6mm) 3/32 (2.4mm)

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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 is important 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 to increase 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 indicated 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 composition is for the final casting (.0), or for the ingot (.1 or .2 depending on purity limits).
Cast Aluminum Alloys:
Aluminum

Si+Cu Al Cu and/or Mg Si 1XX.X 2XX.X 3XX.X 4XX.X

Mg 5XX.X

Zn 7XX.X

Sn Other 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 electrical 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-treatable series used for general-purpose fabrication and buildup. 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.

Wrought Aluminum Alloys:

Aluminum

Al 1XXX

Cu 2XXX

Mn 3XXX

Si 4XXX

Mg 5XXX

Mg/Si 6XXX

Zn 7XXX

Other 8XXX

NonHeat-Treatable

Heat-Treatable

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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. In fact, the 5XXX series has the highest strength of the nonheat-treatable aluminum alloys. It is used for chemical 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 automotive, 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 welded with 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 magnesium and copper produces the highest strength heattreatable aluminum alloy. It is primarily used in the aircraft industry. The weldability of the 7XXX series is compromised 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 are widely used for bicycle frames and other extruded applications. 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 heattreatable 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 aluminum 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 temper applicable only to alloys which age spontaneously at room temperature after solution heat-treatment. Solution heat-treatment involves heat treating the alloy to 1000F (538C) to bring the alloying elements 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-treated and artificially aged.

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CHEMICAL COMPOSITION OF SUPERGLAZE MIG WIRES 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.

TABLE 1 WIRE CHEMICAL COMPOSITION (%)

(Single Values are Maximum, except of Aluminum)
AWS A5.10-92 ASME SFA-5.10 Classification ER1100 & Alloy 1050(a)(h) ER2319(a) ER4043 ER4047 ER4643(a) Alloy 5052(a)(h) Alloy 5056(a)(h) Alloy 5087(h) Alloy 5154(a)(h) ER5183 ER5356 ER5554(a) ER5556(a) ER5654(a) Alloy 5754(a)(h) (a) (b) (c) (d) (e)

Mn 0.05 0.20-0.40 0.05 0.15 0.05 0.10 0.05-0.20 0.6-1.0 0.10 0.50-1.0 0.05-0.20 0.50-1.0 0.50-1.0 0.01
(f)

Si
(b)

Fe
(b)

Mg 0.02 0.05 0.10 0.10-0.30 2.2-2.8 4.5-5.6 4.3-5.2 3.1-3.9 4.3-5.2 4.5-5.5 2.4-3.0 4.7-5.5 3.1-3.9 2.6-3.6

Cr 0.15-0.35 0.05-0.20 0.05-0.25 0.15-0.35 0.05-0.25 0.05-0.20 0.05-0.20 0.05-0.20 0.15-0.35 0.05-0.30 (f)

Cu 0.05-0.20 5.8-6.8 0.30 0.30 0.10 0.10 0.10 0.05 0.10 0.10 0.10 0.10 0.10 0.05 0.05

Ti 0.10-0.20 0.20 0.15 0.15 0.20 0.15 0.06-0.20 0.05-0.20 0.05-0.20 0.05-0.15 0.15

Zn 0.10 0.10 0.10 0.20 0.10 0.10 0.10 0.25 0.20 0.25 0.10 0.25 0.25 0.20 0.20

Be

Others(g) 0.05

Al 99.0 rest rest rest rest rest rest rest rest rest rest rest rest rest rest

0.20 4.5-6.0 11.0-13.0 3.6-4.6 0.25 0.30 0.25 0.25 0.40 0.25 0.25 0.25
(c)

0.30 0.8 0.8 0.8 0.40 0.40 0.40 0.40 0.40 0.40 0.40 0.40
(c)

(d) (d) (d) (d) (d) (d) (d) (d) (d) (d) (d) (d) (d) (d)

0.05(e) 0.05 0.05 0.05 0.05 0.05 0.10-0.20 0.05 0.05 0.05 0.05 0.05 0.05 0.05

0.25

0.40

SuperGlaze alloy available on a made-to-order basis. Silicon + Iron shall not exceed 0.95%. Silicon + Iron shall not exceed 0.45%. Beryllium shall not exceed 0.0008%. Vanadium content shall be 0.05 - 0.15% and Zirconium content shall be 0.10 - 0.25%.

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.

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ELECTRODE DESCRIPTION AND SELECTION ER1100 The 1XXX series of filler alloys make the softest 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 similar compositions. ER1100 is suitable in most cases although it contains a small amount of Cu. ER2319 This alloy is designed to weld the 2XXX alloys 2219 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 specifically 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-silicide (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 provide 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 150F (65C). ER4643 This alloy is designed for one purpose only. There is enough magnesium added to this alloy so that it will 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. It is 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 doesnt 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 tensile 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 applications where the service temperature exceeds 150F (65C). Prolonged exposure above 150F (65C) will sensitize these alloys to stress corrosion cracking and result 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 automotive 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 welding 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 to requirements. The Filler Metal Guide, Table 2 on page 8, covers both wrought and cast alloys.

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TABLE 2 - FILLER METAL GUIDE

319.0 333.0 354.0 355.0 380.0 356.0 357.0 359.0 413.0 444.0 443.0 7005 k 7039 710.0 711.0 712.0 6070 6061 6063 6101 6201 6151 6351 6951

Base Metal 1060 1070 1080 1350 1100 3003 2014 2036 2219 2519 3004

511.0 512.0 513.0 514.0

5456

5454

5154 5254 a 5086

5083

5052 5005 5652 a 5050

3004

2219 2519

2014 2036

1100 3003

1060 1070 1080 1350

4145 c, i

4043 i, f

5356 c,e,i

5356 c,e,i

4043 i

4043 i

5356 c

4043 i

5356 c,e,i

5356 c

5356 c

4043 i

1100 c

4043

4145

4145

1100 c

1188 j

4145 c,i 4145 g 4145 g,c,i 4043 i 4043 i 4043 i

4043 i,f 4145

5356 c,e,i

5356 c,e,i

4043 i 4145

4043 i 4145

5356 c

4043 e,i

5356 c,e,i

5356 c

5356 c

4043 e,i

4043 e

4043 e

4145

4145

1100 c

4145 g 4043 4043 i 5654 b 5654 b 5654 b 5356 e 5356 b 5654 a 5554 c,e 4043 i 5654 b 5654 b 5654 b 5356 e 5356 b 5654 a,b 4043 4043 4043 i 4043 e,i 4043 e,i 5654 a,b,c 4043 4043 2319 c,f,i

4145 g

4145 c,i 4043 i 4043 i 4043 b,i 5356 c,e,i 5356 c,e,i 4043 b,i

4043 i 5654 b 5654 b 5654 b 5356 e 5356 e 5654 b 5654 b 5356 e

4043 i 5356 e 5356 e 5356 e 5183 e 5356 e 5356 b 5356 b 5556 e

4043 f,i 4043 e 4043 e 5356 b,c 5356 e 5356 e 5356 b,c 5356 b,c 5356 e

4043 f,i 4043 b 4043 b 5356 b,c 5356 e 5356 e 5356 b,c 5356 b,c 5356 e

5356 e 5356 e 5356 b 5183 b 5356 e 5356 b 5356 b 5556 e

5356 e 5356 e 5356 e 5356 e 5356 e

5356 e 5356 e 5356 e 5183 e

4043 e 4043 d,e

4043 e

5005 5050 5052 5652 5083

5086

5154 5254 a 5454 4043 i

4043 b,i 5356 c,e,i

5456

6061 6063 6101 6201 6151 6351 6951 6070

4145 c,i

4043 f,i

5356 b,c

5356 b,c,i

4043 b,i

4043 b,i

4145 c,i

4043 f,i

5356 c,e

5356 c,e,i

4043 e,i

7005 k 7039 710.0 4043 711.0 i 712.0 511.0 512.0 513.0 514.0 356.0 357.0 359.0 413.0 444.0 443.0 319.0 333.0 354.0 355.0 380.0

4043 b,i

5356 b

5356 e

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 [150F (65C)] 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.

ADDITIONAL GUIDELINES
4043 b,i 5654 b,d

1.

4145 c,i

4043 d,i

2. 3.

Service conditions such as immersion in fresh or salt water, exposure to specific chemicals, or exposure sustained high temperature (over 150F) may limit the choice of filler metals. Filler alloys 5356, 5183, 5556 and 5654 are not recommended for sustained elevated temperature service. Guide lines in this table apply to gas shielded arc welding processes. Where no filler metal is listed, the base metal combination is not recommended for welding.

4145 d,c,i

The serviceability of a product or structure utilizing this type of information is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying this type of information. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements.

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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 properties 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 the weld 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 approximately 1000F (538C) for a short time. This is called a solution 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 400F (204C) for one hour. At this point, the material is said to be in the T6 temper. Most heattreatable alloys are sold in this temper.

When T4 or T6 materials are welded, the heat of welding 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), so that the reduction can be significant. However, it is possible to restore the mechanical properties, 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 400F (204C) for one hour. A much larger improvement will be observed if the material is welded in the T4 temper and aged at 400F (204C) 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 properties. This last course of action is clearly not always practical, 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 150F (65C)] of 5XXX series alloys containing more than 3% magnesium however, these alloys eventually become sensitive to stress corrosion. In this type of service 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 resistance lowered 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.

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TABLE 3 TYPICAL AS-WELDED MECHANICAL PROPERTIES OF GMAW WELDED BUTT JOINTS

Base Alloy Filler Alloy Tensile Strength (ksi) (MPa) Yield Strength (ksi) (MPa) Elongation Tensile Free Bend (%) (%)

Nonheat-Treatable Alloys 1100 3003 5005 5050 5052 5083 5086 1100 1100 5356 5356 5356 5183 5356 13 16 16 23 28 43 39 90 110 110 158 193 296 269 4.5 7 7 8 13 24 17 31 48 48 55 90 165 117 29 24 15 18 19 16 17 54 58 32 36 39 34 38

Heat-Treatable Alloys 2219-T87 6061-T6 6061-T6 6063-T6 7005-T53 2319 4043 5356 4043 5556 35 27 30 20 44 241 186 207 138 303 26 18 19 12 25 179 124 131 83 172 3 8 11 8 10 15 16 25 16 33

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III. HOW PHYSICAL PROPERTIES EFFECT WELDING PROCEDURES

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. CHART 1 100
(100%) Electrical Conductivity

80

60

%
40

(59%)

(42%) (29%)

20

0 Copper 1100 4043 5356

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.

CHART 2 WFS vs. AMPS 550 500 450 400 (in./min)

WFS 350
300 250 200 150 150 175
5356 Amps 150 175 200 225 250 WFS 325 385 440 495 545 Amps 150 175 200 225 250

3/64 5356 3/64 4043

200

225
4043 WFS 270 315 360 410 460

250

AMPS

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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 welding 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.

FIGURE 2

1/2" (12.7mm) 1/4" (6.4mm)

3/4" (19.0mm)

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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 housekeeping 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 condensation in the torch cable. Dont move material inside when it is cold outside and weld on it immediately. Condensation can form on the surface of the material. Dont 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 -70F (-56C). Make sure the welding wire doesnt have residual drawing lubricant on its surface. Use a slight leading angle (10 to 15 Degrees), but dont 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.

FIGURE 3 EFFECT OF SHIELDING GAS

100% Argon

100% Argon

100% Helium

100% Helium

Additionally, the addition of helium to the argon shielding gas can reduce porosity levels. Although the mechanism for this phenomenon isnt 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

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IV. RECOMMENDED PROCEDURES

CLEANING BASE MATERIAL The hydrated aluminum oxides or hydrocarbon contamination 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 3720F (2049C), but the base metal melts much lower at about 1200F (649C). 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 aluminum and some of the techniques used to clean off aluminum oxide, such as a stainless steel bristle wire brush, solvents and etching solutions.

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 deviation from 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 intermittent 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. FIGURE 6

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 aluminum 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 beforehand under simulated production conditions. This helps avoid mistakes caused by lack of experience.

The finish of a MIG weld in aluminum leaves a crater that is very susceptible to cracking. FIGURE 7

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

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

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TABLE 4 - TYPICAL SEMIAUTOMATIC ALUMINUM MIG PROCEDURES FOR GROOVE WELDING

Metal Thickness (In.) 1/16 3/32 1/8 3/16 Joint Weld Edge Spacing Position(1) Preparation(2) (In.) F F F F, V, H, O F, V, H F, V, H, O F, V, H F, V, H O F, V H, O F F V, H O F, V O, H F F V, H O F, V O, H F F V, H, O F V, H, O A G A G A G B F F H H B F F F H H C-90 F F F H H C-60 F F E E None 3/32 None 1/8 0-3/32 3/16 0-1/16 0-1/16 0-1/16 3/32-3/16 3/16 0-3/32 0-3/32 0-3/32 0-3/32 1/8-1/4 1/4 0-3/32 0-3/32 0-3/32 0-3/32 1/4-3/8 3/8 0-3/32 0-1/8 0-1/16 0-1/16 0-1/16 Electrode Diameter (In.) .030 .030 .030-3/64 .030 .030-3/64 .030-3/64 .030-3/64 3/64 3/64 3/64-1/16 3/64 3/64-1/16 3/64-1/16 3/64 3/64-1/16 3/64-1/16 3/64-1/16 1/16 1/16 1/16 1/16 1/16 1/16 3/32 3/32 1/16 1/16 1/16 Arc DC (EP)(3) Voltage(3) (Amps) (Volts) 70-110 70-110 90-150 110-130 120-150 110-135 130-=175 140-180 140-175 140-185 130-175 175-200 185-225 165-190 180-200 175-225 170-200 225-290 210-275 190-220 200-250 210-290 190-260 340-400 325-375 240-300 270-330 230-280 15-20 15-20 18-22 18-23 20-24 19-23 22-26 23-27 23-27 23-27 23-27 24-28 24-29 25-29 25-29 25-29 25-29 26-29 26-29 26-29 26-29 26-29 26-29 26-31 26-31 26-30 26-30 26-30 Argon Gas Flow (cfh) 25 25 30 30 30 30 35 35 60 35 60 40 40 45 60 40 60 50 50 55 80 50 80 60 60 80 60 80 Arc Travel Speed (ipm/pass) 25-45 25-45 25-45 25-30 24-30 18-28 24-30 24-30 24-30 24-30 25-35 24-30 24-30 25-35 25-35 24-30 25-40 20-30 24-35 24-30 25-40 24-30 25-40 14-20 16-20 24-30 16-24 16-24 Approx. Electrode Consump. (lb/100 ft.) 1.5 2 1.8 2 2 3 4 5 5 8 10 6 8 10 10 12 12 16 18 20 20 35 50 50 70 75 70 75

Weld Passes 1 1 1 1 1 1 1F, 1R 1 2F 2 3 1F, 1R 2 3F, 1R 3F, 1R 2-3 4-6 1F, 1R 2F, 1R 3F, 1R 5F, 1R 4 8-10 3F, 1R 4F, 1R 8F, 1R 3F, 3R 6F, 6R

1/4

3/8

3/4

(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
Metal Thickness(1) (In.) 3/32 1/8 Electrode Diameter (In.) .030 .030-3/64 .030 .030-3/64 3/64 .030-3/64 .030-3/64 3/64-1/16 3/64 3/64-1/16 1/16 1/16 1/16 3/32 1/16 1/16 DC (EP)(4) (Amps) 100-130 125-150 110-130 115-140 180-210 130-175 130-190 170-240 170-210 190-220 240-300 190-240 200-240 360-380 260-310 275-310 Arc Voltage(4) (Volts) 18-22 20-24 19-23 20-24 22-26 21-25 22-26 24-28 23-27 24-28 26-29 24-27 25-28 26-30 25-20 25-29 Argon Gas Flow (cfh) 30 30 30 40 30 35 45 40 45 60 50 60 85 60 70 85 Arc Approx. Travel Electrode Speed Consump.(3) (ipm/pass) (lb/100 ft.) 24-30 24-30 24-30 24-30 24-30 24-30 24-30 24-30 24-30 24-30 18-25 24-30 24-30 18-25 24-30 24-30 1.8 2 2 2 4.5 4.5 4.5 7 7 7 17 17 17 66 66 66

Weld Position(2) F, V, H, O F V, H O F V, H O F V, H O F H,V O F H, V O

Weld Passes(3) 1 1 1 1 1 1 1 1 1 1 1 3 3 4 4-6 10

3/16

1/4

3/8

3/4

(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.

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V. PULSING AND WAVEFORM MANIPULATION

EVOLUTION OF POWER SUPPLIES FOR GAS METAL 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 the welder 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 in heavy 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 fluctuations can result in cold lap weld defects in aluminum. Because of this, for many years it was strongly recommended 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 supplies 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 is that the peak current is high enough to get spray transfer and we transfer metal across the arc in spray transfer while the arc is at this current level. No metal is transferred across the arc during the periods of background current. However, the average current, and average heat input can now be significantly lower than if we dont 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 welding process for certain specific characteristics. Today, Lincolns 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 spatter 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 generated by the arc. The general term heat input does not consider the efficiency of the heat transferred to the base material and weld.

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ANATOMY 0F A WAVEFORM What exactly is the waveform control technology provided 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 maintain 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 advancement 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 reaches peak 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 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 background current as it decreases has the effect of increasing 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 waveform 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.

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 apperance 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 software. The ArcScope gives the engineer a visual compilation 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 spatter, cold lap and burn-throughs with the use of waveform technology. This has been done repeatedly in applications 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 currents or they can be created to follow a very wide range of material thicknesses with a broad range of wire feed speed. FIGURE 9

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VI. TROUBLESHOOTING GUIDE

PROBLEM Porosity CAUSE Turbulence of weld pool Moisture from environment Hydrogen contamination of materials. Contaminated shielding gas or inadequate flow Fast cooling rate weld pool POSSIBLE CURE Shorten contact tip to work distance. Keep wire dry and covered. Clean base metal prior to welding. Keep dew point below -70F (-57C) increase flow rate, shield from air disturbance, too small gas nozzle. Use higher welding current and/or slower speed. Preheat base metal. In vertical welding, wrong progression weld vertical up. Select filler metal with lower melting and solidification temperatures. Avoid weld pool chemistry of 0.5-2.0% Si and 1.0-3.0% Mg. Avoid Mg2Si eutectic problems (5XXX welded with 4XXX). Reduce base metal dilution of weld through increased bevel angle and spacing. 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. Add filler metal in GTAW of heat-treatable alloys. Increase wire feed (CC), or reduce arc voltage (CV). Replace. Replace. Replace. Replace. Match contact tube size to wire. Reduce duty cycle, use water-cooled gun. Change polarity. Reconnect ground. Pre-purge gas shielding. Change polarity. 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. Keep electrodes covered. Clean, degrease parent material. Clean joint area.

Weld Cracking

Improper choice of filler metal Critical chemistry range

Inadequate edge preparation or spacing Incorrect weld technique

No filler metal

Burnback

Insufficient wire feed Irregular wire feed Electrode kinked Flexible conduit too long Worn or dirty liner Worn or dirty contact tip Arcing in contact tube Over-heating of the gun Wrong polarity Improper grounding No shielding gas Wrong polarity

Poor Arc Starting

Dirty Welds

Inadequate gas coverage

Dirty electrodes Dirty parent material Oxide film or water on parent

-19-

PROBLEM Unstable Arc

CAUSE Poor electrical connections Dirt in joint area Arc blow Welding current too high, travel speed too low, and/or arc length too long. Insufficient welding current Travel speed too high Arc length too long Dirty parent material Inadequate joint spacing or edge preparation Oxide on base material or wire Insufficient depth or improper shape of the back-gouge.

POSSIBLE CURE Check electrical connections. Clean, degrease joint area. Do not weld in area of strong magnetic field. Modify welding parameters.

Weld Bead Excessively Wide

Inadequate Penetration, Incomplete Fusion

Increase current. Reduce travel speed. Decrease arc length. Clean, degrease joint area. Redesign joint. Clean. Increase depth of back-gouge (U- or V- type).

Mismatch of Color After Anodizing

Improper alloy selection

Match color selection. Avoid 4XXX filler wires, 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-

SAFETY

WARNING
CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline 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 powered equipment.

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.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

____________________________________________________ 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 refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine 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 safety guards to perfor m required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts. ___________________________________________________ 1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

ELECTRIC AND MAGNETIC FIELDS may 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 and welding 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 electrode 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.

___________________________________________________ 1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

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

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SAFETY
ELECTRIC SHOCK can kill.
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.

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ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays. 4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

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 par ts 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 GASES can 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 manufacturers instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employers safety practices. MSDS forms are available from your welding distributor or from the manufacturer. 5.e. Also see item 1.b.

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SAFETY
WELDING SPARKS can cause fire or explosion. CYLINDER may explode if damaged.

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6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic 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 hazardous situations. Refer to Safety in Welding and Cutting (ANSI Standard Z49.1) and the operating information for the equipment being used. 6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard. 6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been cleaned. For information, purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances, AWS F4.1 from the American Welding Society (see address above). 6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode. 6.f. Sparks and spatter are thrown from the welding arc. Wear oil 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. Always wear safety glasses with side shields when in a welding area. 6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail. 6.h. Also see item 1.c.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition. 7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support. 7.c. Cylinders should be located: Away from areas where they may be struck or subjected to physical damage. A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame. 7.d. Never allow the electrode, electrode holder or any other electrically hot parts to touch a cylinder. 7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve. 7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use. 7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, Precautions for Safe Handling of Compressed Gases in Cylinders, available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY powered equipment.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturers recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturers recommendations.

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SAFETY
PRCAUTIONS DE SRET

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Pour votre propre protection lire et observer toutes les instructions et les prcautions de sret specifiques qui parraissent dans ce manuel aussi bien que les prcautions de sret gnrales suivantes: Sret Pour Soudage A LArc 1. Protegez-vous contre la secousse lectrique: a. Les circuits llectrode et la pice sont sous tension quand la machine souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vtements mouills. Porter des gants secs et sans trous pour isoler les mains. b. Faire trs attention de bien sisoler 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse. c. Maintenir le porte-lectrode, la pince de masse, le cble de soudage et la machine souder en bon et sr tat defonctionnement. d.Ne jamais plonger le porte-lectrode dans leau pour le refroidir. e. Ne jamais toucher simultanment les parties sous tension des porte-lectrodes connects deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines. f. Si on utilise la machine souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-lectrode sapplicuent aussi au pistolet de soudage. 2. Dans le cas de travail au dessus du niveau du sol, se protger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le cble-lectrode autour de nimporte quelle partie du corps. 3. Un coup darc peut tre plus svre quun coup de soliel, donc: a. Utiliser un bon masque avec un verre filtrant appropri ainsi quun verre blanc afin de se protger les yeux du rayonnement de larc et des projections quand on soude ou quand on regarde larc. b. Porter des vtements convenables afin de protger la peau de soudeur et des aides contre le rayonnement de larc. c. Protger lautre personnel travaillant proximit au soudage laide dcrans appropris et non-inflammables. 4. Des gouttes de laitier en fusion sont mises de larc de soudage. Se protger avec des vtements de protection libres de lhuile, tels que les gants en cuir, chemise paisse, pantalons sans revers, et chaussures montantes. 5. Toujours porter des lunettes de scurit dans la zone de soudage. Utiliser des lunettes avec crans lateraux dans les zones o lon pique le laitier.

6. Eloigner les matriaux inflammables ou les recouvrir afin de prvenir tout risque dincendie d aux tincelles. 7. Quand on ne soude pas, poser la pince une endroit isol de la masse. Un court-circuit accidental peut provoquer un chauffement et un risque dincendie. 8. Sassurer que la masse est connecte le plus prs possible de la zone de travail quil est pratique de le faire. Si on place la masse sur la charpente de la construction ou dautres endroits loigns de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, cbles de grue, ou autres circuits. Cela peut provoquer des risques dincendie ou dechauffement des chaines et des cbles jusqu ce quils se rompent. 9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particulirement important pour le soudage de tles galvanises plombes, ou cadmies ou tout autre mtal qui produit des fumes toxiques. 10. Ne pas souder en prsence de vapeurs de chlore provenant doprations de dgraissage, nettoyage ou pistolage. La chaleur ou les rayons de larc peuvent ragir avec les vapeurs du solvant pour produire du phosgne (gas fortement toxique) ou autres produits irritants. 11. Pour obtenir de plus amples renseignements sur la sret, voir le code Code for safety in welding and cutting CSA Standard W 117.2-1974.

PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR

1. Relier la terre le chassis du poste conformement au code de llectricit et aux recommendations du fabricant. Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre. 2. Autant que possible, Iinstallation et lentretien du poste seront effectus par un lectricien qualifi. 3. Avant de faires des travaux linterieur de poste, la debrancher linterrupteur la boite de fusibles. 4. Garder tous les couvercles et dispositifs de sret leur place.

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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 customers 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 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.

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LINCOLN NORTH AMERICA

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Cast Iron/Non-Ferrous C8.100 2/02