Welding Precautions - Aluminum

WELDING PRECAUTIONS - ALUMINUM

Correct equipment and cleaning procedures must be used when welding aluminum.

Gas-metal-arc-welding (GMAW) or MIG and Gas-tungsten-arc-welding (GTAW) or TIG are used for welding aluminum and aluminum alloys.
- The correct protective clothing should always be worn.
- Proper ventilation must be provided to avoid the accumulation of poisonous gases.
- Disconnect the battery ground cable from the battery.
- Disconnect on-vehicle modules and protect them from possible heat damage and electrical currents when welding.
- Use a stainless steel wire brush to remove aluminum oxides.
- Make sure the surface is clean and free of foreign materials.
- Use degreasers that do not contain hydrocarbons.
- Do not use a wire brush that has been used on stainless or carbon steel.
- Follow equipment manufacturer's prescribed procedures as aluminum and aluminum alloys have a higher thermal conductivity and lower melting point which can lead to easier burn through.
- A test weld should always be carried out on a test sample.
- Preheating the aluminum workpiece can help prevent weld cracking. The preheating temperature should not exceed 110°C (230°F).
- Use a temperature indicator to prevent overheating.
- Attach the ground clamp as close as possible to the work area.
- Types of filler rods to use when TIG welding aluminum:
- Aluminum-silicon alloy.
- Aluminum-magnesium alloy.

- Adequate power supply needs to be used to make sure of correct equipment performance.
- Corrosion protection needs to be restored whenever it is necessary to sand or grind through painted surfaces or E-coat, or when bare metal repairs are carried out. Refer to Restoring Corrosion Protection Following Repair.