ALUMINUM WELDING

Harald Weber
Fronius International GmbH
Global Tech Support Mangement
Froniusplatz 1
4600 Wels /Austria
Aluminium properties
Aluminum compared to Steel

Aluminum Steel
Density (g/cm³) 2,7 7,85
Tensile strength (N/mm²) 160 360
Melting range (C°) 595 – 640 1460 – 1530
Thermal conductivity (W/m.K) 235 75
Advantages and reasons for the use of Aluminum

/ Lower unit weight and high strength

(cold rolling can increase the strength of pure Al from 65 N/mm² to 80 N/mm²)
/ Aluminum alloys such as AlMg3 (5754) can reach 200 N/mm²
/ Resistant against climatic influences
/ Good toughness at sub zero temperatures
/ Very good suitable for production for continuous cast profiles
The most important Aluminum alloying elements

Magnesium (Mg) Manganese (Mn) Copper (Cu) Silicon (Si)

/ 0,3 – 7 % of Mg in / 0,3 – 1,2% of Mn in / Less than 5% of Cu in / Up to 12% Si in

Aluminum Aluminum Aluminum Aluminum
/ Decreases melting point
/ Increases strength / Increases strength / Increases strength / Coarse grained
/ Finer granulation / High corrosion resistance / Harden able / Resistance against
/ Corrosion resistance / Low corrosion resistance cracking
/ Lowest shrinkage
dimension
Aluminum and there alloys

/ 1000 series = pure Al (>99,0%) natural hard

/ 2000 series = main alloy Copper (Cu) harden able
/ 3000 series = main alloy Manganese (Mn) naturally hard
/ 4000 series = main alloy Silicon (Si) naturally hard
/ 5000 series = main alloy Magnesium (Mg) naturally hard
/ 6000 series = main alloy Mg + Si harden able
/ 7000 series = main alloy Zinc (Zn) age harden able
/ 8000 series = other elements e.g. Lithium
Classification

Aluminum

Wrought Aluminum alloys Aluminum casting materials

Al + Si (4000 series)

Harden able wrought alloys Non harden able wrought alloys

/ AlMgSi (6060) / AlMg3 (5754)
/ AlZn 4,5 Mg1 (7020) / AlMg 4,5Mn (5183)
 Non harden able wrought alloys (3000 & 5000 series)

Magnesium (Mg) & Manganese (Mn)

/ 3000 series = Manganese(Mn)
/ 5000 series = Magnesium (Mg)

/ Non age harden able Aluminum alloys do not harden after heat treatment,

/ Those Aluminum alloys derive their higher strength thru solid solution strengthening, but in the
HEZ they loose some tensile strength after welding.

/ Magnesium (Mg) & Manganese (Mn) can increase the tensile strength up to about 280N/mm²
Harden able wrought alloys (2000, 6000 & 7000 series)

Magnesium (Mg) & Silicon (Si) / Zinc (Zn) / Copper (Cu)

The following Aluminum alloys can be hardened by heat treatment up to about 450 N/mm²

/ 2000 series = Copper (Cu)

/ 6000 series = Magnesium (Mg) + Silicon (Si)
/ 7000 series = Zinc (Zn)

AW 7020 (AlZn4,5Mg1)
/ good weld ability
/ increases strength by being cold aged (after 60-90 days)
Aluminum and there alloys

Tensile strenght Rm in MPa

Cracking tendency of Aluminum (heat cracking)

Cra c king te nde nc y

Mg

0 1 2 3 4 5 % Alloy c ontent

Silicon
Silicon
Aluminum in common use
Al 99,5 1000 series AlCu 2000 series AlMn 3000 series

/Lorem
Wireipsum dolorlines
for power sit amet, consec /Lorem ipsum
Aircraft anddolor sit amet,industry
Aerospace consec /Lorem ipsum dolor sit amet, consec
Radiators
tetuer adipiscing elit. Aenean commodo tetuer adipiscing elit. Aenean commodo tetuer adipiscing elit. Aenean commodo
ligula
/ Wiresegetfordolor.
transformers ligula
/ Noteget dolor. can be welded
all alloys ligula
/ Aireget dolor.
conditions
Aenean massa. Cum sociis natoque Aenean massa. Cum sociis natoque Aenean massa. Cum sociis natoque
Cooling
/pena fins
tibus etmagnis dis parturient /penaDonec
tibus quam
etmagnisfelis,disultricies nec,
parturient Pots
/pena (due
tibus to high dis
etmagnis heatparturient
resistance)
montes, nasc etur ridiculus mus. Donec pellentesque eu, pretium quis,
montes, nasc etur ridiculus mus. Donec sem. montes, nasc etur ridiculus mus. Donec
quam felis, ultricies nec, pellentesque eu,
/ Jewellery quam felis, ultricies nec, pellentesque eu, quam
/ ……… felis, ultricies nec, pellentesque eu,
pretium quis, sem.watches
e.g. aluminum pretium quis, sem. pretium quis, sem.
Aluminum in common use
AlSi 4000 series AlMg 5000 series AlMgSi 6000 series

/Lorem ipsum dolor

Aluminum cast sit amet, consec /Lorem ipsumvessels
Pressure dolor sit amet, consec /Lorem ipsum
Mostly useddolor sit automotive
in the amet, consec
tetuer adipiscing elit. Aenean commodo tetuer
/ Boat and shipelit.
adipiscing Aenean commodo
building tetuer adipiscing elit. Aenean commodo
industry
ligula eget dolor.cast
/ Continuous ligula eget dolor.
/ Bridges ligula eget dolor.
5000 massa.
series has / Windows
Aenean massa. Cum sociis natoque /Aenean Cumthesociis
highest strength
natoque Aenean massa. Cum sociis natoque
Cylinder
/pena heads dis parturient
tibus etmagnis pena tibus etmagnis dis parturientalloys.
of all non hard able Aluminum pena tibus etmagnis dis parturient
montes, nasc etur ridiculus mus. Donec / Very high
montes, nasccorrosion resistance
etur ridiculus mus. Donec Doorsnasc etur ridiculus mus. Donec
/montes,
quam felis, ultricies
/ Aluminum rims nec, pellentesque eu, /quam
Notfelis,
use ultricies
able for nec,
high pellentesque
temp. if Mg eu, quam felis, ultricies nec, pellentesque eu,
pretium quis, sem. pretium
amount quis,
is sem.
higher than 3% (max. 65C) pretium quis, sem.
/ Continuous cast
due to stress corrosion cracking / …..
Aluminum in common use
AlZn 7000 series AlLi 8000 series

/Lorem ipsum
Military dolor sit amet, consec
industry /Lorem ipsum
Under dolor sit amet, consec
development
tetuer adipiscing elit. Aenean commodo tetuer adipiscing elit. Aenean commodo
ligula eget dolor.
/ Aerospace industry ligula eget dolor.
/ Already used in Aerospace industry
and Aircraft industry
Aenean massa. Cum sociis natoque Aenean massa. Cum sociis natoque
Aircraft
/pena tibus industry
etmagnis dis parturient pena tibus etmagnis dis parturient
montes, nasc etur ridiculus mus. Donec montes, nasc etur ridiculus mus. Donec
quam felis, ultricies
/ Automotive nec, pellentesque eu,
industry quam felis, ultricies nec, pellentesque eu,
pretium quis, sem. pretium quis, sem.
Choosing the right filler metal

Filler Metal Base metal

Al2O3 ( Aluminum oxide)

Aluminum oxide (Al2O3) melting point ～2050

Aluminum melting point ～660

/ Use Stainless steel wire brush to clean / Milling instead of grinding

/ Keep surface free form oil and grease (C) / Use cotton gloves
/ Use acetone to clean surface / Use special Aluminum file or grinding discs
/ Oxide layer will be always there / Separate Aluminum and other Metals
Preheating

/ Preheat not more than 100 to 200°C

/ Use Acetylene – Oxygen
/ Do not use Propane (H²)
Tip for Aluminum welding

Edges not chamfered Chamfered edges

/ Oxides not fully flushed off / Oxides fully flushed off the end
Shielding gases for Aluminum welding

Argon Helium

/ Common / Thermal conductivity 9 x better than argon

Lorem ipsum dolorshielding gastetuer
sit amet, consec foradipiscing
Aluminum elit. Lorem ipsum dolor sit amet, consec tetuer adipiscing elit.
.
Aenean commodo ligula eget dolor.
/ Good arc stability Higher
/Aenean travel
commodo ligulaspeed
eget dolor.

Aenean massa. Cum sociis natoque pena tibus etmagnis dis

/ Deep finger shaped penetration Lessmassa.
/Aenean porosity
Cum sociis natoque pena tibus etmagnis
parturient montes, nasc etur ridiculus mus. Donec quam dis parturient montes, nasc etur ridiculus mus. Donec quam
felis, ultricies nec, pellentesque eu, pretium quis, sem. /felis,Wide
ultricies&nec,
deep penetration
pellentesque eu, pretium quis, sem.
Shielding gases for Aluminum welding

Argon Argon + 30% Helium Argon + 50% Helium Argon + 70% Helium

/ Gas flow: 42cfh / Gas flow: 42cfh / Gas flow: 59cfh / Gas flow: 80cfh

Gas Ionization energy (eV)

Argon (Ar) 15,8

Helium (He) 24,6

 Smut Control
/ Alloy Selection
/ Shorter Arc - Lower Arc Voltage
/ Increase Gas Flow / Cup Size
/ Gas Type - Argon Vs Helium
/ Gas Contamination - Water
/ Gun Leaks
/ Weld Position
/ Pulse Equipment
Aluminum Oxide And Welding Conditions

Facts
Aluminum oxide – self limited to 40 to 50 atoms in thickness
is not generally detrimental to welding.
Thick hydrated oxide films breaks down to cause porosity
and hydrated oxide inclusions

Conclusion
Control metal contact with moisture and welding control of
hydrated oxide inclusions and porosity will be controlled
 Storage Of Aluminum
/ Reason
/ All Aluminum Is Covered With A Thin, Hard, Adhered Oxide Film
Which Is:
/ Porous
/ Hydrates
/ Increases In Thickness Over Time

/ Recommended Storage
/ Base Metal
/ Position Vertically
/ Allow For Air Circulation
/ Heated / Constant Temperature
/ Electrode
/ Maintain In Heated Uniform Temperature Area
/ Hold In Weld Area 24 Hours Before Unpacking
/ Unpackaged Spool – Hot Boxed (40To 60o C)
/ Dust Cover On Welder
 Welding Discontinuities
Causes And Corrections
Weld Incomplete Incomplete
Porosity Cracking Penetration Fusion

24
 Porosity

Scattered Porosity Revealed By Fractured Nick – Break Specimen

25
 Porosity – Size & Distribution
< 1/64" Diameter Disregard
1/64" < 1/16" Diameter Fine
Size 1/16" < 1/8" Diameter Medium
= or > 1/8" Diameter Large
Scattered Distribution

Least Effect On Mechanical Properties Acceptable If Less Than Allowed By D1.2

Clustered Distribution

Result Of Varying Welding Conditions May Or May Not Be Acceptable See D1.2
Aligned Distribution

Related To Lack Of Fusion Or Penetration Seldom Acceptable See D1.2

26
 Porosity

Absorption Of Hydrogen Into The Molten Weld Zone Then Rejected

During Cooling. The Gas Becomes Trapped Within The Weld Deposit
In The Form Of Bubbles.
Sources Of Hydrogen Hydrocarbons Hydrated Oxides
Moisture

/ Turbulence Of Weld Pool

/ Contamination
/ Moisture - Atmosphere, Shield Gas & Dew Point
/ Cooling Rate Of Weld Pool

27
Effect Of Porosity On Tensile Strength

60 Base Plate Filler Metal

50 6061 T651 5356
40

30

20
Design Allowable Is 24 Ksi (165 Mpa)
10

0
0 5 10 15 20 25 30 35 40 45 50
Total Porosity - Volume %
28
 Weld Cracking - HOT

/ Choice Of Filler Metal

/ Lower Melting & Solidification Point - Molten During Maximum
Contraction Stresses

/ Smaller Freezing Zone

Avoid Critical Chemistry Ranges

/ Si 0.5% To 2.0%
/ Example: 4043 20% ( Electrode )
/ 1100 80% ( Base )

/ Avoid Welding 5XXX Esp. ( 5086, 5083, 5456 ) With 4043 Or

4XXX. Mgsi Eutectic Problems

44
/ Avoid Mg Range Up To 3.0% In Weld
 Weld Cracking - HOT
Welding Practices
/Clamp To Minimize Stress
/Narrow Heat Zone / Rapid Traverse Speed
/Minimize Super-Heated Molten Metal Grain Size Effect
/Slight Back Hand Angle Puddle Weld – Convex
/Proper Weld Size – Not Too Small

Geometry Of Welds

/ Greater Angles Reduce Dilution And Cracking

Reduce Thermal Stresses
• Reduce Excessive Localized Stresses
•
45 Preheat Total Structure
Tungsten Inert Gas Process
TIG Welding

/ High seam quality

/ Can be used in all positions
/ Possible to mechanize
TIG Welding

Gaseous shield

Tungsten electrode

Filler material

Welding direction
TIG Welding AC Mode
TIG Welding AC Mode
Special features for Aluminium

Automatic Cap sharping

Multiple wave forms

Balance adjustment

AC Frequence adjustable
TIG Welding Applications

Material thikness: 7mm Pipe diameter:400mm

Welding speed: 10 cm/min Parameter: 330-370A
Position: PA
Metal Inert Gas Process
MIG Welding

/ Easy to handle
/ Can be used in all positions
/ Possible to mechanize
/ High travel speed
/ High deposition rate
MIG Welding
MIG Welding
MIG Welding

/
MIG Welding (manuel)

Perfect feeding for aluminum wires

MIG Welding
Special features for Aluminium

Special 4 Step

Syncro Pulse

Spatter free Ignition & optimized weld end

Arclenght & penetration stabilizer

PMC Mix Drive /PMC Ripple Drive

(only for automized push pull system)
MIG Welding
MIG Welding
MIG Welding
MIG Welding
MIG Welding
Special features for Aluminium

Special 4 Step

Syncro Pulse

Spatter free Ignition & optimized weld end

CMT Mix Synergic lines

MIG Welding
MIG Welding Applications
PMC RIPPLE DRIVE
MIG Welding Applications

Telecommunication

/ PMC Manual
/ Replaced GTAW process
/ Significantly reduced part weld time
/ Easy to handle
/ Low distortion
MIG Welding Applications

/ CMT + Syncropulse
/ 100% Argon
/ ER5356 .045”
/ Beat out TIG process due to simplicity and productivity
MIG Welding Applications
CMT-Mix High Speed
Cmt-Mix overlapp weld

1mm Almg3

100% Ar / Alsi5 1,2mm

Welding speed: 4,5m/min

MIG Welding Applications
Automotive axle part
CMT Mix
Welding speed: 100cm/min
AlSi5 1,2mm 100%Argon
Double wire Process
CMT Twin & Time Twin
TIME TWIN & CMT Twin
TIME TWIN & CMT Twin
TIME TWIN & CMT Twin

LHSB

/ Processes can be mixed

/ High arc stability
/ Synchronized pulse arc technology
/ Full control of both wire electrodes
TIME TWIN & CMT Twin Applications

/ Travel speed: 250cm/min

/ AlMg 4,5Mn 1,6mm
/ Gas: 70%Ar/30He
/ Position: PA
TIME TWIN & CMT Twin Applications
/ Material thickness: 3,2mm
/ Travel speed: 210cm/min
Result:
High travel speed => less distortion
Very high quality
Reliable power source
TIME TWIN & CMT Twin Applications

/ Material thickness: 12,5mm

/ Travel speed: 100cm/min
Result:
High travel speed => less distortion
Very high quality
Less spatter
Savings on shielding gas
(by using 100%Argon)
TIME Twin & CMT Twin Applications

Vs:50cm/min A-dimension: 6,9mm(in 1layer)

Wire: 2x 1,2mm ALSi5 Shieldgas: 70Ar/ 30He
Position: PB
Laser Hybrid Process
LaserHybrid
Laser Hybrid

Requirements to joining technology:

/ Higher gap tolerance between the aluminum profiles and sheets

compared to pure laser
/ Low distortion to have a perfect fitting to the car body
/ High welding speed to reduce cycle time
/ High economic, by decreasing filler wire and gas
/ Using light weight potential and create high stiffness on the parts
/ High weld seam quality due to stabilisation of the arc
Laser Hybrid
Laserbeam Electrode

Laser induced plasma Arc

Shielding gas cloud

Fusion zone

Keyhole

Direction of
Workpiece welding
Laser Hybrid
BEISPIELSEITE

68
Laser Hybrid
Laser Hybrid

Laser: LaserHybrid:
PL: 2000 W PL: 1500 W
vS : 1m/min U: 20V
I: 95 A (PS: 1,9 kW)
vS: 1m/min
Laser Hybrid

Laser LASER HYBRID MIG

PL: 3000W PL: 2500W PL: 0W
PGMA: 0 W PGMA: 2500W PGMA: 6000W
Laser Hybrid Applications

Laserpower: 3,5kW
1,2mm AlSi5
Gas 100%Argon
Weldingspeed: 250cm/min
 Laser Hybrid Applications
Mercedes S-Class:
Laserbeam
Door Mercedes S-Class
Torch GMA

AA6082 Arc

Melting zone
Al-cast (AlSi10Mg)

Welding direction

Wire consumption: - 80%

vs: 4,5 m/min

Laser Hybrid Applications

Filler wire: AlSi5

Base material: AlMg3

/ Welding speed: 2,4 m/min

/ Reduction of shielding gas: 40%
/ Saving filler wire: 30%
/ No quality control needed
Laser Hybrid Applications
Resistance Spot Welding process
Delta Spot
DELTASPOT
PRINCIPLE: THE PROCESS TAPE
DELTASPOT
DELTASPOT

Advantages of the process tape

/ Process tape protects electrode
/ No alloying of
/ surface coatings (e.g. Prima corrosion protection)
/ Base material (e.g. aluminium)
/ Every spot weld is welded
under the same contact conditions
/ Very high reproducibility
/ Excellent surface quality
/ No reworking necessary
/ Ideal for spot welding materials with a high degree
of electrode contamination
DELTASPOT

Robotic X-450R Robotic C350R Stationary

Spot welding gun X450R Spot welding gun C350R Spot welding system
/ Electrode force 6 kN / Electrode force 8 kN / Electrode force 8 kN
/ Throat depth 450 mm / Throat depth 350 mm / Throat depth 1000
17.7 in. 13.8 in. mm 39.4 in.
/ Gun weight 168 kg / Gun weight 162 kg / Gun weight 950 kg
(with transformer) 370 lb (with transformer) 357 lb (with transformer) 2100 lb
DELTASPOT Application
Sector & applications
Automotive component supply industry
Aluminium die casting doors

/ Material combination
/ Aluminium reinforcing plate 1.5 mm
/ Aluminium die casting door 3.0 mm

/ Reasons for using DeltaSpot

/ Perfect spot weld quality
/ Excellent surface quality
/ Saving on rework through lower electrode
impression and no welding spatter
/ Used in series production since 2008
DELTASPOT Application
Aluminium electric car
DELTASPOT Application
Aluminum front cover for convertible

System: C-350 G2 robotic

Material combination: EN-AW 6016 1.3 + 1.3 mm

Decision criteria for DeltaSpot:

/ No expulsion (spatter)
/ Joint quality
/ No tip dressing

Advantage for customer:

/ Massive increase in output due to no tip
dressing
/ Overall high weld quality
DELTASPOT Application
Battery cover plate

System: C-450 G2 robotic

Material combination: 6xxx aluminum 1.5 mm

2 and 3 sheet stackup

Decision criteria for DeltaSpot:

/ No expulsion (spatter)
/ Joint quality
/ No tip dressing

Advantage for customer:

/ Massive increase in output due to no tip
dressing
/ Overall high weld quality
 DELTASPOT Application
Steel fuel tanks

System: C-450 G2 robotic

Material combination:
Mild steel 1,4 mm (aluminum rich organic compound)
to Mild steel SnZn 0.8 mm

Decision criteria for DeltaSpot:

/ No expulsion (spatter)
/ Joint quality
/ No tip dressing

Advantage for customer:

/ Massive increase in output due to no tip dressing
/ Overall high weld quality
Thank you…!!!
Alle Angaben sind trotz sorgfältiger Bearbeitung ohne Gewähr - Haftung ausgeschlossen.
Urheberrecht und Copyright: Sämtliche Rechte vorbehalten. Der nicht anders gekennzeichnete Inhalt dieser Präsentation bzw. Dokumente(s) (Texte, Bilder, Grafiken, Animationen usw.) unterliegt dem Urheberrecht und den Gesetzen
zum Schutze geistigen Eigentums. Der Inhalt darf weder insgesamt noch in Teilen ohne vorherige ausdrückliche Genehmigung von Fronius für private oder für kommerzielle Zwecke verwendet, kopiert oder verändert werden.