"I can't weld aluminium" | Problems & Solutions

1. Cracks and breaks: due to its high thermodynamic reactivity (unstable chemical composition), Aluminium can crack or weaken when exposed to stress.
   
   Solution: choose an addition material that has a chemical composition with lower sensitivity and good weldability (ALSi5 (ER4043), for example).
    
2. Deformations: Aluminium has a low melting point (the temperature at which a substance changes from a solid to a liquid state) and therefore it is a metal with a tendency to become deformed.
   
   Solution: Use a MIG/GMAW process with pulsation capacity. This process is done through an energy source, combining a low background current and high breaking current, to avoid excess heat or burning.
    
3. Discoloration: when welding Aluminium, magnesium oxides can accumulate at the base of the material, decolorating the metal.
   
   Solution: select a suitable shielding gas for the process (high purity argon, for example). Furthermore, it is recommended to keep the stick-out (distance between the contact tip and the workpiece) and to use a correct and stable welding angle – something that can be easily corrected with the high precision of robotic welding solutions. These precautions will ensure less accumulation of magnesium oxides and will help prevent further discoloration of the material.
    
4. Time: due to the specificities of Aluminium, its welding is a process that takes time. Even more experienced welders take their time to weld this material.
   
   Solution: robots are a key player here. In addition to protecting workers from the wear and tear that these processes cause to the health of welders, the robot has a more consistent work and can move from one weld to another quickly, thus speeding up the entire process.
    
5. Wire pull: Aluminium wire is softer than other types of metal wire, making it more difficult to pass a welding torch than other filler metals.
   
   Solution: It is recommended to use a welding torch with a pull-push wire traction system. Using these tools will help stabilize the wire pulling process.

We solve your problem

Many of these problems with Aluminium welding are easily overcome with robotic welding. By automating your production, cycle times will be faster and more consistent, with no interruptions in the production and with better weld quality.

The biggest asset for welding Aluminium is undoubtedly the automation of the production, and for that you can talk to Motofil sales team or technicians. Contact us and make your request for a quote. With over 40 years of experience in the market, we have robotic automation solutions for your business.

Our company works so that customers can have their technical and production needs satisfied, making the ideal solutions for optimizing their production.