TIG Aluminum 3G butt joint

This Video is on a TIG Aluminum 3G butt joint.

The main goal on a butt joint is usually getting complete penetration on the back side of the weld.

Of course the right settings and details help like amperage, AC balance, AC frequency, tungsten type and size, and filler rod type and size all matter but there is another thing that matters an awful lot too and is often overlooked.

Cleaning the sheared edge of the joint is one of the most important factors in achieving smooth penetration all the way thru the back side of the joint.

for this video I used a clean dedicated file to clean the edges.

I also showed an example of using the wrong type of flap disc on the edge.

The wrong abrasive can heat up the aluminum and smear oxides.

There are flap discs and wheels made specifically for aluminum that wont load up and wont smear oxides.  ( one wheel I have used is the Walter Alu flap disc...I am out of stock right now on weldmonger.com but you can easily find them with a google search).

A clean dedicated file designed for aluminum is always a good choice and wont introduce grit or smear oxides.

Oxides on the edge of a butt joint can prevent smooth even penetration.

A dedicated aluminum file can be better than a flap disc for prepping aluminum butt joints for several reasons:

1. Preventing Contamination: Flap discs, especially if used on other metals, can introduce contaminants like steel particles into the aluminum, which can cause issues like porosity and weak welds. A dedicated aluminum file avoids this problem, as it is specifically used for aluminum only.
2. Smoother Surface Finish: Aluminum is a soft metal, and using a flap disc can sometimes remove too much material or cause deep scratches. A file offers more controlled material removal, resulting in a smoother surface, which is ideal for welding.
3. Avoiding Overheating: Flap discs can generate excessive heat, which may cause aluminum to gum up or distort. Files generate little to no heat, keeping the aluminum’s properties intact.
4. Minimal Material Loss: Flap discs can remove more material than necessary, thinning the aluminum. A file provides better precision, allowing you to remove only the oxidized layer without compromising the material’s thickness.

 

Check out this video on 7 Awesome Tips for Tig welding aluminum

TIG welding aluminum can be very enjoyable.  But TIG welding dirty aluminum is no fun.