How to Weld Sheet Aluminum

Aluminum transfers heat quickly, which is why aluminum is used to make heat sinks for electrical equipment. Therefore, you need to employ a welding method that produces a lot of heat and produces the heat quickly. TIG welding offers you the ability to precisely control the heat coming from the TIG torch to the weld joint of the aluminum sheet and keep the surface of the aluminum sheets clear of welding spatter. Welding spatter is when molten melted does not bond to the weld bead and releases on the surface of the metal surrounding the weld bead.

Instructions

1

Place the two sheets of aluminum flat on the surface of the metal welding table.

2

Put on your leather work gloves, safety glasses and face shield.

3

Attach the 60-grit flapper wheel to the 4-inch grinder.

4

Slide one edge of the aluminum sheet off the side of the metal welding table 3 inches.

5

Secure the aluminum sheet to the metal welding table with the two C-clamps. You need to place one C-clamp on each end of the aluminum sheet, where the end of the sheet intersects the side of the metal welding table.

6

Lower your face shield and run the flapper wheel along the edge of the aluminum sheet that overhangs the metal welding table. The bevel needs to have a taper between 15 and 30 degrees.

7

Release the C-clamps and exchange the beveled aluminum sheet for the second piece of aluminum. Repeat Steps 4 through 7 to bevel the other sheet of aluminum.

8

Attach the flow meter of the TIG welder to the bottle of argon shielding gas and place the TIG welder's grounding clamp to the metal welding table.

9

Exchange your face shield for the welding hood and turn on the TIG welder.

10

Set the TIG welder to weld the aluminum sheet. You will find a guide on the TIG welder that states the proper settings based on the thickness aluminum sheets.

11

Slide the beveled sides of the aluminum sheets together, align the tungsten of the TIG torch with the weld joint and lower your welding hood.

12

Start and hold the arc of the TIG welder on the aluminum sheet for two seconds and then stop the arc to tack weld the sheets of aluminum. Repeat this step to place a tack weld every 4 inches along the entire length of aluminum weld joint.

13

Align the TIG torch with the top of the tacked weld joint, hold a length of aluminum filler rod in one hand and lower your welding hood.

14

Start the welding arc and feed the filler rod into the weld joint to weld together the sheets of aluminum.

15

Remove the welding hood and put on the face shield.

16

Attach the 4-inch wire wheel to the grinder and lower your face shield.

17

Run the wire wheel along the length of the carbon from the weld bead.

18

Allow the weld joint to thoroughly cool before handling the welded aluminum sheets.