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Best practices while welding Aluminum

Best practices while welding Aluminum

Best practices while welding Aluminum poses some unique challenges, as it has low melting point and high thermal conductivity. It is prone to burn through thin sections and can experience lack of fusion to thick areas. While welding aluminum cracks, welds smut/soot and porosity are more concern defects.

Even aluminum has ability to resist corrosion, high strength to weight ratio, as well as its high electrical conductivity make it an excellent choice for many applications from aerospace to energy exchangers, fabrication and automotive body panels and frames..

To skip detrimental effects on productivity and quality, it is urgent to recognize the causes of welding defects, important steps to prevent them and look at the ways to rectify the occurred errors.

  • Causes of cracking in aluminum welds


  1. During gas metal arc welding (GMAW) and gas tungsten arc welding (GTAW), hot cracking, a matter of chemistry and stress cracking, a mechanical matter  can occur. There are three possible factors which increases the probability of hot cracking.
  2. Susceptibility of the base materials to cracks, which means some materials are more prone to cracks than others.
  3. Filler metal implies which metal you are using as filler.
  4. Joint design – some joint design restrict the addition of filler metals.

Stress cracking occurs due to excessive shrinkage on solidification of aluminum welds on cooling. This could be due to a concave bead profile, a too slow travel speed, a highly steady joint, or dejection in the end of the weld .

  • How cracks can be Prevented


  1. Choosing a lower crack sensitive metal, as a filler metal having a good chemistry with weld metal, can prevent cracks.
  2. For best choice, one must refer a reputable filler metal selection guide because not all aluminum filler metals are suitable for every aluminum base material. Most of the filler guide provides the characteristics of weld metals such as –cracking, ductility, strength, corrosion resistance, post weld heat treatment and toughness. Select a higher rating filler metal, if cracking is concerned.
  3. Even an appropriate joint design can prevent cracking. The best option is to go for a beveled groove joint, reason behind choosing such joint is that it allows for the addition of greater amounts of filler metal, to increases the base metal dilution and prevent joint from cracking.
  4. To prevent stress cracking, preference must be given to filler metal containing silicon because this type of filler metal lowers shrinkage stresses, particularly in areas which are sensitive in cracks like the beginning and end of the weld. In addition to it, stress cracking can be reduced by increasing your travel speed. However, preheating reduces the residual stress levels present in base metal during and after welding. Appropriate heat input is key for good welds. Best practices while welding Aluminum


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  1. Kevin says:

    oh no its all in good debate and it seems to be the norm on the net. but back to the tphroy thing you dont have to win nothing to get awards and trophies. its evident in every sector in every place in america. i can weld with my eyes shut standing on my head with one arm. most welds to have slag inclusion. but since you are an expert welder tell me with all the experiance this guy has that it isnt normal to have it stick as much. it stuck every other second and he doesnt square nothing

    1. Kenisha says:

      That would indeed make for some happy elves! Count me in. At first I thought it was chresarute liqueur, which is impossible to get around here. I like Midori, too, though. Shirley

  2. tanveer malik says:

    I’m Aluminum Tig Mig Welder Looking For Job

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