Aluminum Welding History and Testing of Aluminum Welding Adam Robertson Duke Schimmer Euft Kruithof December 10, 2006 ENGR 45, Santa Rosa Junior College, SRJC

History Friederich Wohler discovers aluminum C.L. Coffin described the Gas Tungsten Arc Welding (GTAW) beginnings when a weld was made in non-oxidizing atmospheres Aluminum Spot Welding saw application in the Aviation Industry 1940s - With World War II GTAW was found to be useful for welding magnesium in fighter planes, and later found it could weld stainless steel and aluminum High Frequency stabilized AC tungsten-arc welding is used for aluminum alloys US Navy uses inert-gas metal arc welding for aluminum hulls of 100 feet in length

More History The Russian Welding program in Space began by producing Electron Beam welds, welding an AMG6 And DM-20 aluminum alloys with the Vulkan process The American Astronauts used Electron Beam welding process in June 1973, welding Aluminum Alloy 2219-T The first welded aluminum sphere for a liquefied natural gas tanker was made TWI of Cambridge England develops the Friction Stir Weld (FSW) process in its laboratory. No shielding gas or filler metal is required. Metals joined successfully include, the 2xxx, 6xxx,and 7xxx series aluminum. NASA is the first Us venture which welded the massive fuel tank for the space shuttle.

Industries Aerospace Automotive Watercraft Bicycle Piping Cable Beverage Marking

The Aluminum Advantage Lightweight Excellent Thermal/Electrical Conductivity Can be Very Ductile or Rigid Resistance to Oxidation Corrosion Resistance Excellent Strength/Weight Ratio Reflective Non-Combustible Doesn’t Spark Non-Magnetic

Disadvantages (In some applications) Difficult to Form Difficult to Weld Dissipates Heat Quickly Material is Expensive Susceptible to Cyclic Wear Brittle

Aluminum Welding Tutorial Start by striking an arc on the parent metal in the desired area Heat the metal until a sufficiently sized puddle of molten metal is formed Begin running a bead by dipping the filler rod into the puddle, while managing the size of the puddle by controlling the amperage of the machine with the foot pedal Watch out for burning through the metal by using too much heat, or using too little heat and not getting sufficient penetration

Welding Theory Video

Video Demonstration

Pictures

Pictures

Descriptions of Tests Rockwell Hardness Tests –Took Hardness Data for an Aluminum Plate with a Weld Down the Center Tinius Olsen Bend Test –Compared the Bend Displacement of Two Welded Plates to One Solid Plate

Hardness Testing

Hardness Testing Results

Bend Test

Bend Test Results

Weld Weakness The material weakness in welded metals is not in the weld itself, but the area immediately surrounding it:

Weld Weakness – The Movie

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