Welding and Cutting Aluminum

May 6, 2013

To weld aluminum both TIG (Tungsten Inert Gas) and pulsed MIG (Metal Inert Gas) welding are used.  Argon gas is used to create an oxygen free atmosphere over the weld.

All the aluminum is cut by a computer controlled water jet. The idea behind it is very simple. A huge, computer controlled plotter instead of a pen or an ink jet has on its business end a small water jets that thanks to its force and some added sand cuts through practically anything. The pressure of the water jet is of course monstrous, around 4000 bar. In comparison, the water pressure of where the Titanic, has sunk is "only" about 500 bar, if you assume that the relic lies under 5000 meters of oceanThe big advantage of cutting aluminum with a water jet is that the alloy does not get hot, like when cutting it with a plasma jet .

 

Equipment

Miller Synchrowave TIG Welding Equipment 

Miler Synchrowave 351 CC . AC/DC welding power source
OCIM torch, water cooled

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Miller

The following manual provided by Miller is also part of this section:

Miller Synchrowave 351 Manual

 

Miller Dynasty 200 DX TIG Welding Equipment 

The Miler Dynasty TIG welding equipment is a portable machine that can weld aluminum, steel and stainless steel.  An electronic power supply assures a small and portable unit.

Currently with a type SA 18 torch for 3.2 and 2.4 mm tungsten electrode.

miller AL settings

The settings displayed above are for Aluminum welding.

1st button:     for Aluminum use AC, for Stainless steel use DC.

2nd button:    top with high frequency, arch starts with tungsten at a distance, middle without HF, touch material with
                        the electrode and then lift to get arch.

3rd button:    top keep pressed to weld, middle press to weld, press again to stop, bottom not used

4th button:    pulsed, used for thin material.

5th button:    top base A  (usually 10), middle ones up and down ramp A, use down ramp if no pedal by momentarily
                        not pressing button.  Bottom final A (usually 10).

6th button:    post gas time.  For Aluminum the higher the A, the longer postgas, for 190 A 10-14 sec.
                        Electrode must stay white.

7th button:    For Aluminum to balance wave (usually 70 - 80)

Last button:    press to get back to set welding A.

 

Data Welding srl
Miller

The following manual provided by Miller is also part of this section:

Miller Dynasty 200 manual
Miller Dynasty 200 manuale italiano

 

Miller XMT MIG Welding Equipment 

The Miller XMT MIG welding equipment consists of the following units:

Miller XMT 304
XR control
Optima 304 remote pulsing pendant control
XR edge 30A air cooled push-pull gun

 

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Miller

The following manual provided by Miller is also part of this section:

Miller XMT 304 manual

 

TIG Welding Wire

For welding 5083 alloy and 5083 with 6060 alloy a 5356 wire is used.


For welding 6060 with itself a 6060 wire is used.

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Metalli Trafilati Laminati

The following certificate is also part of this section:

MTL tig welding wire certificate

 

MIG Welding Wire

For welding 5083 alloy and 5083 with 6060 alloy a 5356 wire is used.

For welding 6060 with itself a 6060 wire is used.

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Tungsten Electrodes

For TIG welding tungsten electrodes are used.

Gold:        both for Al and Inox
Green:      Al (pure tungsten)
Red:        Inox 

3.2 and 2.4 mm diameter.

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The following certificate is also part of this section:

Wolfram industries tungsten electrodes certificate

 

 

Operator Welding Certificate

For RINA certification one welder must have a  welding certificate.

The following certificate is also part of this section:

Fulvia Frigo welding certificate

 

 

2013-05-06
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