subject: Skills Training Required to Work With Aluminium Wire [print this page] Copyright (c) 2010 Nadine DavisAs techniques for manufacturing products made from aluminium become increasingly sophisticated, more industrial and consumer applications for this amazing metal are being found. Aluminium can now be found in almost every home, business and manufacturing complex in the industrialised world ' from a drink can to the family vehicle, it is hard to imagine life without it. Lightweight and corrosion-resistant, aluminium is especially suitable for use near the ocean, and many ocean front buildings are now replacing their old, corroded and dangerous balcony railings with aluminium railings which will resist ocean spray. Some specialised knowledge is needed, however, to get the best out of this amazing resource.Aluminium can be a difficult metal to work with, especially for those experienced only in steel welding, and care must be taken to get the best result. Aluminium Fabrication welders are aware that what works for steel may not work for aluminium. There are three areas in particular that need to be addressed:1. The set-up and associated techniques.2. Power sources.3. Three ways to feed the aluminium wire.Because of the sheer size of this particular topic, we will discuss set-up within this article, and subsequent areas will be covered in future articles.The Set-up and associated techniques.The following changes to steel settings and equipment are required:=> Liner and Wire Guides: a helically wound steel liner is not suitable as it would scratch the soft aluminium wire creating shavings. Use a Teflon or nylon liner and wire guides to reduce friction and eliminate shavings.=> Drive Rolls: Use a U-shaped groove in the drive rolls to eliminate sharp edges that will shave off the aluminium wire. Reduce the tension on the drive roll to stop the wire from crushing during feeding.=> Contact Tips: A bigger hole is needed for aluminium than for steel, as the aluminium expands further than steel when heated. Purchase contact tips designed especially for aluminium to prevent poor electrical contact.=> Brake Tension: Set the brake tension on the wire spindle more loosely than for steel to reduce the force needed to pull the wire off the spool.=> Gun Cables: Keep the gun as straight as possible to minimize tangling. The column strength of aluminium makes it much more difficult to feed.The softness of the metal is the most difficult thing that people new to welding aluminium must consider. There is always the possibility of scratching of the soft wire and the creation of shavings which cause other problems to surface, so individual welders who are used to fabrication work must make recommendations for changes in the initial setup stages.
Skills Training Required to Work With Aluminium Wire
