Which Equipment Is Good for Welding Aluminum Alloys? Is Oxidation Prone To Occur?

Aluminum alloy is lightweight and strong, making it widely used in automotive, home appliance, and aviation parts. However, many people struggle when welding aluminum alloy: which equipment should they choose, and how can they avoid oxidation issues? Today, I’ll explain it straightforwardly to help you select the right equipment and avoid oxidation problems in aluminum alloy welding.

 I. Choosing the Right Equipment for Aluminum Alloy Welding

There are several welding equipment options for aluminum alloy. As a manufacturer of spot welders, laser welding machines, and robotic laser welding machines, we understand the strengths of each type. You can choose based on your production volume and precision requirements:

1. Spot Welder: The Best Choice for Thin-Wall Aluminum Alloy Batch Welding

  - Aluminum alloy spot welders use electrodes to apply pressure and generate heat through contact resistance to melt the alloy and form a weld point. The advantage is speed; each weld point takes only 0.1-1 second. This is ideal for thin-wall aluminum alloy (0.1-3 mm) in batch welding, such as aluminum alloy joints in home appliance casings and small aluminum alloy parts.

  - However, aluminum alloy is highly conductive and dissipates heat quickly. You need a specialized spot welder with high current and short welding parameters to avoid incomplete welding. Electrodes can oxidize and wear out due to high temperatures, so regular grinding or replacement is necessary to maintain stable welding.

2. Laser Welding Machine: Essential for High-Precision Aluminum Alloy Welding

  - Laser welding machines use a high-energy laser beam to melt aluminum alloy. The heat-affected zone is very small, allowing precise control of the weld seam. The resulting weld seam is smooth and requires little or no post-weld treatment. It can weld aluminum alloy from 0.05-8 mm thick and is suitable for high-precision and appearance-critical applications, such as aluminum alloy frames in smartphones and precision instrument parts.

  - When welding aluminum alloy, choose a laser welding machine with a pulse function to reduce heat input and prevent deformation. Also, use argon gas protection to prevent oxidation during welding, ensuring weld strength and appearance.

3. Robotic Laser Welding Machine: The Preferred Option for Large-Scale Standardized Aluminum Alloy Welding

  - Robotic laser welding machines combine laser welding with robotic arms to achieve automated and standardized welding, capable of continuous 24-hour operation. The welding precision is stable and not affected by human operation differences, making it suitable for large-scale aluminum alloy welding, such as batch production of aluminum alloy car doors and chassis components in the automotive industry.

  - It can handle a wide range of aluminum alloy thicknesses and complex welding trajectories, such as circumferential welds on irregular aluminum alloy parts, making it ideal for companies looking to scale up production and reduce labor costs.

4. Traditional Equipment: Meeting Basic Welding Needs

  - TIG Welder: Uses a tungsten electrode to create an arc, with argon gas protecting the molten pool. It requires manual wire feeding. It offers precise temperature control and aesthetically pleasing welds, suitable for thin-wall aluminum alloy (0.5-5 mm) in precision welding, such as aluminum alloy jewelry and small parts. However, it has low welding efficiency and is best for small-batch production.

  - MIG Welder: Features automatic wire feeding, with welding speeds 3-5 times faster than TIG welding. It is suitable for medium-thick aluminum alloy (3-20 mm) in batch welding, such as aluminum alloy pipes and equipment frames. However, it requires high-purity (99.99%+) argon gas to prevent porosity.

II. Oxidation Issues in Aluminum Alloy Welding and How to Avoid Them

Many people worry about oxidation when welding aluminum alloy. This is due to the nature of aluminum alloy, but with proper understanding and protection, it can be effectively avoided:

1. The Root Cause of Oxidation

  - The surface of aluminum alloy readily reacts with air to form an oxide layer (mainly Al₂O₃), which has a melting point of up to 2050°C, much higher than the alloy’s own melting point (around 660°C). If this oxide layer is not thoroughly removed before welding, it will enter the molten pool, causing slag inclusion and porosity in the weld seam. It also hinders the fusion of the alloy, affecting weld strength. Moreover, during welding, if the molten pool is not properly protected, oxygen in the air will continue to react with it, exacerbating oxidation.

2. Key Measures to Prevent Oxidation

  - Thoroughly clean the oxide layer before welding: mechanically brush the aluminum alloy surface with a stainless steel wire brush or soak it in a specialized aluminum alloy cleaner to dissolve the oxide layer. After cleaning, complete the welding within 4 hours to prevent secondary oxidation.

If you have welding machine requirements, please contact Ms. Zhao

E-Mail: pdkj@gd-pw.com

Phone: +86-13631765713