The Everyday

Pocket Handbook
for Gas Metal Arc
Welding (GMAW)
of Aluminum

Number 8 in a series

Compiled as a useful tool for

on-the-job welding personnel by the
AWS Product Development Committee
1
 Edited by
Lee G. Kvidahl
Ingalls Shipbuilding

1998 by American Welding Society. All rights reserved

Printed in the United States of America

NOTE: Although care was taken in choosing and presenting the data in this guide, AWS cannot guarantee that it is
error free. Further, this guide is not intended to be an exhaustive treatment of the topic and therefore may not include all
available information, including with respect to safety and health issues. By publishing this guide, AWS does not insure
anyone using the information it contains against any liability or injury to property or persons arising from that use.

2
 Table of Contents
Basic Safety Precautions ...........................................4
Typical Joint Geometries for Arc Welding
of Aluminum.........................................................6
Designations for Wrought Alloy Groups ..................9
Chemical Composition of Wrought Aluminum
Filler Metals........................................................10
Typical Aluminum Filler Metal Properties
(As-Welded Condition).......................................11
Guide to the Selection of Filler Metal for General
Purpose Welding .................................................12
Influence of Shielding Gas on Weld Profile............15
Typical Procedures for Gas Metal Arc Welding
of Groove Welds in Aluminum Alloys with
Argon Shielding..................................................16
Typical Procedures for Gas Metal Arc Welding
of Fillet Welds in Aluminum Alloys with
Argon Shielding..................................................18
Typical Procedures for Flat Position Gas Metal
Arc Welding Groove Welds in Aluminum
Alloys with Large Diameter Electrodes..............19
3
Joint Geometry Types ............................................. 21
Typical Procedures for Gas Metal Arc Welding
of Fillet Welds in Aluminum Alloys with
Large Diameter Electrodes and Argon
Shielding............................................................. 22
Aluminum Welding Wire........................................ 23
Preparation of Aluminum for Welding ................... 24
Storage of Base Metal......................................... 24
Storage of Consumables ..................................... 24
Plate Edge Preparation........................................ 24
Cleaning Prior to Welding .................................. 24
Oxide Removal with Wire Brushing................... 25
Shielding Gas Purity ........................................... 25
Tips to Make the Aluminum Welding Job
Easier .................................................................. 26
Troubleshooting ...................................................... 27
Basic Welding Symbols and Their Location
Significance ........................................................ 28
Location of Elements of a Welding Symbol ........... 30
 Basic Safety Precautions
Burn Protection. Molten metal, sparks, slag,
and hot work surfaces are produced by welding,
cutting, and allied processes. These can cause
burns if precautionary measures are not used.
Workers should wear protective clothing made
of fire-resistant material. Pant cuffs, open pock-
ets, or other places on clothing that can catch
and retain molten metal or sparks should not be
worn. High-top shoes or leather leggings and
fire-resistant gloves should be worn. Pant legs
should be worn over the outside of high-top
shoes. Helmets or hand shields that provide pro-
tection for the face, neck, and ears, and a head
covering to protect the head should be used. In
addition, appropriate eye protection should be
used.
4
Electrical Hazards. Electric shock can kill.
However, it can be avoided. Live electrical parts
should not be touched. The manufacturers
instructions and recommended safe practices
should be read and understood. Faulty installa-
tion, improper grounding, and incorrect opera-
tion and maintenance of electrical equipment
are all sources of danger.
All electrical equipment and the workpiece
should be grounded. The workpiece lead is
not a ground lead. It is used only to complete
the welding circuit. A separate connection is
required to ground the workpiece. The work-
piece should not be mistaken for a ground
connection.
Fumes and Gases. Many welding, cutting,
and allied processes produce fumes and gases
which may be harmful to health. Avoid breath-
ing the air in the fume plume directly above the
arc. Do not weld in a confined area without a
ventilation system. Use point-of-welding fume
removal when welding galvanized steel, zinc,
lead, cadmium, chromium, manganese, brass, or
bronze. Do not weld on piping or containers
that have held hazardous materials unless the
containers have been inerted properly.
Compressed Gas Cylinders. Keep caps on
cylinders when not in use. Make sure that gas
5
cylinders are chained to a wall or other struc-
tural support.
Radiation. Arc welding may produce ultra-
violet, infrared, or light radiation. Always wear
protective clothing and eye protection to pro-
tect the skin and eyes from radiation. Shield
others from light radiation from your welding
operation.
Refer to AWS/ANSI Z49.1, Safety in Welding,
Cutting, and Allied Processes, for additional
information.
Typical Joint Geometries for Arc Welding of Aluminum (Not to Scale)
6
Typical Joint Geometries for Arc Welding of Aluminum (Continued) (Not to Scale)
7
Typical Joint Geometries for Arc Welding of Aluminum (Continued)

8
 Designations for Wrought Alloy Groups
A system of four-digit numerical designations is used to identify wrought aluminum alloys. The first digit indicates the
alloy group as follows:
Aluminum, 99.0% and greater 1XXX*
Major Alloying Element:
Copper 2XXX
Manganese 3XXX
Silicon 4XXX
Magnesium 5XXX
Magnesium and Silicon 6XXX
Zinc 7XXX
Other elements 8XXX
Unused series 9XXX
*For 1XXX series, the last two digits indicate the minimum aluminum purity (e.g., 1060 is 99.60% Al minimum). The second digit in all groups
indicates consecutive modifications of an original alloy, such as 5154, 5254, 5454, and 5654 alloys.

9
 Chemical Composition of Wrought Aluminum Filler Metals
Other
Filler Elements, wt. %a Elements
Alloy Si Fe Cu Mn Mg Cr Zn Ti Each Total Al
1100 Note b Note b 0.050.20 0.05 0.10 0.05c 0.15 99.0 min.0
1188 0.06 0.06 0.005 0.01 0.01 0.03 0.01 0.01c 99.88 min.
2319 0.20 0.03 5.86.8 0.200.40 0.02 0.10 0.100.20 0.05c 0.15 Remainder
4009d 4.55.5 0.20 1.01.5 0.10 0.450.60 0.10 0.100.20 0.05c 0.15 Remainder
4010e 6.57.5 0.20 0.20 0.10 0.300.45 0.10 0.20 0.05c 0.15 Remainder
4011f 6.57.5 0.20 0.20 0.10 0.450.70 0.10 0.040.20 0.05f 0.15 Remainder
4043 4.56.0 0.80 0.30 0.05 0.05 0.10 0.20 0.05c 0.15 Remainder
4047 11.013.0 0.80 0.30 0.15 0.10 0.20 0.05c 0.15 Remainder
4145 9.310.7 0.80 3.34.7 0.15 0.15 0.15 0.20 0.05c 0.15 Remainder
4643 3.64.6 0.80 0.10 0.05 0.100.30 0.10 0.15 0.05c 0.15 Remainder
5183 0.40 0.40 0.10 0.501.00 4.35.2 0.050.25 0.25 0.15 0.05c 0.15 Remainder
5356 0.25 0.40 0.10 0.050.20 4.55.5 0.050.20 0.10 0.060.20 0.05c 0.15 Remainder
5554 0.25 0.40 0.10 0.501.00 2.43.0 0.050.20 0.25 0.050.20 0.05c 0.15 Remainder
5556 0.25 0.40 0.10 0.501.00 4.75.5 0.050.20 0.25 0.050.20 0.05c 0.15 Remainder
5654 Note g Note g 0.05 0.01 3.13.9 0.150.35 0.20 0.050.15 0.05c 0.15 Remainder
a. Single values are maximum, except where otherwise specified. e. Same composition as A356.0 cast alloy.
b. Silicon plus iron shall not exceed 0.95 percent. f. Beryllium content is 0.04 to 0.07 percent. Same composition
c. Beryllium shall not exceed 0.0008 percent. as A357.0 cast alloy. Used for GTAW rod only.
d. Same composition as C355.0 cast alloy. g. Silicon plus iron shall not exceed 0.45 percent.
10
 Typical Aluminum Filler Metal Properties (As-Welded Condition)

All-Weld-Metal
Minimum Shear Strength Ultimate Tensile Strength

Filler Alloy ksi MPa ksi MPa

1100 7.5 52 13.5 93

2319 16.0 110 37.5 258

4043 11.5 79 29.0 200

5183 18.5 128 41.0 283

5356 17.0 117 38.0 262

5554 17.0 117 33.0 230

5556 20.0 138 42.0 290

5654 12.0 83 32.0 221

11
 Guide to the Selection of Filler Metal for General Purpose Welding a,b,c
319.0, 333.0, 356.0, A356.0, 6005, 6061,
201.0, 354.0, 355.0, 357.0, A357.0, 511.0, 512.0, 7004, 7005, 6063, 6101,
206.0, C355.0. 413.0, 443.0, 513.0, 514.0, 7039, 701.0, 6009, 6010, 6151, 6201,
Base Metal 224.6. A444.0. 535.0. 712.0. 6070. 6351, 6951. 5456 5454
1060, 1070, ER4145 ER4145 ER4043d,e ER5356e,f,g ER5356e,f,g ER4045d,e ER4043e ER5356g ER4043e,g
1080, 1350
1100, 3003, ER4145 ER4145 ER4043d,e ER5356e,f,g ER5356e,f,g ER4043d,e ER4043e ER5356g ER4043e,g
Alc. 3003
2014, 2036 ER4145h ER4145h ER4145 ER4145 ER4145

2219 ER2319d ER4145h ER4145e,f ER4043e ER4043e ER4043d,e ER4043d,e ER4043e

3004, Alc. 3004 ER4043e ER4043e ER5356i ER5356i ER4043e ER4043e,i ER5356g ER5356i
5005, 5050 ER4043e ER4043e ER5356i ER5356i ER4043e ER4043e,i ER5356g ER5356i
5052, 5652l ER4043e ER4043e,i ER5356i ER5356i ER4043e ER5356f,i ER5356i ER5356i
5083 ER5356e,f,g ER5356g ER5183g ER5356g ER5183g ER5356g
5086 ER5356e,f,g ER5356g ER5356g ER5356g ER5356g ER5356g
5154, 5254l ER4043e,i ER5356i ER5356i ER5356i ER5356i ER5356i
a. Service conditions such as immersion in fresh or salt water, exposure to specific chemicals, or a sustained high temperature [over 150 F (66C)] may
limit the choice of filler metals. Filler metals ER5183, ER5356, ER5556, and ER5654 are not recommended for sustained elevated-temperature service.
b. Recommendations in this table apply to gas shielded arc welding processes. For oxyfuel gas welding, only ER1188, ER1100, ER4043, ER4047, and
ER4145 filler metals are ordinarily used.
c. Where no filler metal is listed, the base metal combination is not recommended for welding.
d. ER4145 may be used for some applications.
e. ER4047 may be used for some applications.
f. ER4043 may be used for some applications.
g. ER5183, ER5356, or ER5556 may be used.
h.m. See table footnotes on next page.
12
 Guide to the Selection of Filler Metal for General Purpose Welding a,b,c (Continued)
1100,
,5154, ,5052, 5005, 3004, 2014, 3003, 1060, 1070,
Base Metal l5254l 5086 5083 l5652l 5050, Alc. 3004 2219 2036, Alc. 3003 1080, 1350.
1060, 1070, ER5356e,f,g ER5356g ER5356g ER4043e,g ER1100e,f ER4043e,g ER4145e,f ER4145 ER1100e,f ER1188e,f,k,m
1080, 1350
1100, 3003, ER5356e,f,g ER5356g ER5356g ER4043e,g ER1100e,f ER4043e,g ER4145e,f ER4145 ER1100e,f
Alc. 3003
2014, 2036 ER4145 ER4145 ER4145h ER4145h
2219 ER4043e ER4043e,g ER4043d,e ER4043d,e ER2319d
3004, Alc. 3004 ER5356i ER5356g ER5356g ER5356e,f,i ER5356f,i ER5356f,i
5005, 5050 ER5356i ER5356g ER5356g ER5356e,f,g ER5356f,i
5052, 5652l ER5356i ER5356g ER5356g ER5654f,i,l
5083 ER5356g ER5356g ER5183g
5086 ER5356g ER5356g
5154, 5254l ER5654i,l
a.g. See table footnotes on preceding page.
h. ER2319 may be used for some applications. It can supply high strength when the weldment is postweld solution heat-treated and aged.
i. ER5183, ER5356, ER5554, ER5556, and ER5654 may be used. In some cases, they provide: (1) improved color match after anodizing treatment,
(2) highest weld ductility, and (3) higher weld strength. ER5554 is suitable for sustained elevated-temperature service.
j. ER4643 will provide high strength in 1/2 in. (12.7 mm) and thicker groove welds in 6XXX alloys when postweld solution heat-treated and aged.
k. Filler metal with the same analysis as the base metal is sometimes used. Filler alloys ER4009 or R4009, ER4010 or R4010, and R4011 meet the
chemical composition limits of R-C355.0, R-A356.0, and R-A357.0 alloys, respectively.
l. Base metal alloys 5254 and 5652 are useful for hydrogen peroxide service. ER5654 filler metal is used for welding both alloys for low-temperature
service [150 F (66C) and below].
m. ER1100 may be used for some applications.
13
 Guide to the Selection of Filler Metal for General Purpose Welding a,b,c (Continued)
356.0, A356.0, 6005, 6061,
201.0, 319.0, 333.0, 357.0, A357.0, 511.0, 512.0, 7004, 7005, 6009, 6063, 6101,
206.0, 354.0, 355.0, 413.0, 443.0, 513.0, 514.0, 7039, 701.0, 6010, 6151, 6201,
Base Metal 224.6. C355.0 A444.0 535.0 712.0 6070. 6351, 6951. 5456 5454
5454 ER4043e ER4043e,i ER5356i ER5356i ER4043e ER5356f,i ER5356i ER5554h,i
5456 ER5356e,f,g ER5356g ER5556g ER5356g ER5556g
6005, 6061, 6063, ER4145 ER4145e,f ER4043e,i,j ER5356i ER5356e,f,i ER4043d,e,j ER4043e,i,j
6101, 6151, 6201,
6351, 6951
6009, 6010, 6070 ER4145 ER4145e,f ER4043d,e,j ER4043e ER4043e ER4043e,i,j
7004, 7005, 7039, ER4043e ER4043e,i ER5356i ER5356g
710.0, 712.0
511.0, 512.0, ER4043e,i ER5356i
513.0, 514.0, 535.0
356.0, A356.0, ER4145 ER4145e,f ER4043e,k
357.0, A357.0,
413.0, 443.0,
A444.0
319.0, 333.0, ER4145h ER4145e,f,k
354.0, 355.0,
C355.0
201.0, 206.0, 224.0 ER2319d,k
a.m. See table footnotes on previous page.

14
DIRECT CURRENT ELECTRODE POSITIVE (DCEP)

Influence of Shielding Gas on Weld Profile

15
 Typical Procedures for Gas Metal Arc Welding of
Groove Welds in Aluminum Alloys with Argon Shielding
Section Electrode Welding Arc Shielding Gas
Thickness Joint Root Opening No. of Diameter Current Volt- Flow Ratec Travel Speed
Welding Geom- Weld (DCEP), age,
in. mm Position a etryb in. mm Passes in. mm A V 3
ft /h L/min in./min mm/s
0.06 1.6 F A 0 0 1 .030 0.8 70110 1520 25 12 2545 10.519.0
F G 0.09 2.4
0.09 2.4 F A 0 0 1 .030.047 0.81.2 90150 1822 30 14 2545 10.519.0
F,V,H,O G 0.12 3.2 1 .030 0.8 110130 1823 30 14 2330 9.712.7
0.12 3.2 F,V,H A 0.09 2.4 1 .030.047 0.81.2 120150 2024 30 14 2430 10.212.7
F,V,H,O G 0.19 4.6 1 .030.047 0.81.2 110135 1923 30 14 1828 7.611.8
0.19 4.8 F,V,H B 0.06 1.6 2 .030.047 0.81.2 130175 2226 35 16 2430 10.312.7
F,V,H F 0.06 1.6 1 .047 1.2 140180 2327 35 16 2430 10.312.7
O F 0.06 1.6 2 .047 1.2 140175 2327 60 28 2430 10.312.7
F,V H 0.090.19 2.44.8 2 .047.062 1.21.6 140185 2327 35 16 2430 10.312.7
H,O H 0.19 4.8 3 .047 1.2 130175 2327 60 28 2535 10.514.8
0.25 6.4 F B 0.09 2.4 2 .047.062 1.21.6 175200 2428 40 19 2430 10.312.7
F F 0.09 2.4 2 .047.062 1.21.6 185225 2429 40 19 2430 10.312.7
V,H F 0.09 2.4 3F,1R .047 1.2 165190 2529 45 21 2535 10.514.8
O F 0.09 2.4 3F,1R .047.062 1.21.6 180200 2529 60 28 2535 10.514.8
F,V H 0.120.25 3.36.4 23 .047.062 1.21.6 175225 2529 40 19 2430 10.312.7
O,H H 0.25 6.4 46 .047.062 1.21.6 170200 2529 60 28 2540 10.516.9
a. F = flat; V = vertical; H = horizontal; O = overhead.
b. Refer to pages 68.
c. Nozzle ID = 5/8 to 3/4 in. (15.9 to 19 mm).
16
 Typical Procedures for Gas Metal Arc Welding of
Groove Welds in Aluminum Alloys with Argon Shielding (Continued)
Section Electrode Welding Arc Shielding Gas
Thickness Joint Root Opening No. of Diameter Current Volt- Flow Ratec Travel Speed
Welding Geom- Weld (DCEP), age,
in. mm Position a etryb in. mm Passes in. mm A V 3
ft /h L/min in./min mm/s
0.38 9.6 F C-90 0.09 2.4 1F,1R .062 1.6 225290 2629 50 24 2030 8.512.7
F F 0.09 2.4 2F,1R .062 1.6 210275 2629 50 24 2435 10.314.8
V,H F 0.09 2.4 3F,1R .062 1.6 190220 2629 55 26 2430 10.312.7
O F 0.09 2.4 5F,1R .062 1.6 200250 2629 80 38 2540 10.516.9
F,V H 0.250.38 6.49.6 4 .062 1.6 210290 2629 50 24 2430 10.312.7
O,H H 0.38 9.6 810 .062 1.6 190260 2629 80 38 2540 10.516.9
0.75 19.0 F C-60 0.09 2.3 3F,1R .062.094 1.62.4 340400 2631 60 28 1420 5.98.5
F F 0.12 3.2 4F,1R .094 2.4 325375 2631 60 28 1620 6.88.5
V,H,O F 0.06 1.6 8F,1R .062 1.6 240300 2631 80 38 2430 10.312.7
F E 0.06 1.6 3F,3R .062 1.6 270330 2631 60 28 1624 6.810.3
V,H,O E 0.06 1.6 6F,6R .062 1.6 230280 2631 80 38 1624 6.810.3
a. F = flat; V = vertical; H = horizontal; O = overhead.
b. Refer to pages 68.
c. Nozzle ID = 5/8 to 3/4 in. (15.9 to 19 mm).

17
 Typical Procedures for Gas Metal Arc Welding of
Fillet Welds in Aluminum Alloys with Argon Shielding
Section Welding Shielding Gas
Thickness No. of Electrode Diameter Current Arc Flow Rateb Travel Speed
Welding Weld (DCEP), Voltage,
in. mm aPositiona Passes in. mm A V ft3/h L/min in./min mm/s
0.094 2.4 F,V,H,O 1 0.030 0.8 100130 1822 30 14 2430 1013
0.125 3.2 F 1 0.0300.047 0.81.2 125150 2024 30 14 2430 1013
V,H 1 0.030 0.8 110130 1923 30 14 2430 1013
O 1 0.0300.047 0.81.2 115140 2024 40 19 2430 1013
0.19 4.8 F 1 0.047 1.2 180210 2226 30 14 2430 1013
V,H 1 0.0300.047 0.81.2 130175 2125 35 16 2430 1013
O 1 0.0300.047 0.81.2 130190 2226 45 21 2430 1013
0.25 6.4 F 1 0.0470.062 1.21.6 170240 2428 40 19 2430 1013
V,H 1 0.047 1.2 170210 2327 45 21 2430 1013
O 1 0.0470.062 1.21.6 190220 2428 60 28 2430 1013
0.38 9.6 F 1 0.062 1.6 240300 2629 50 24 1825 811
H,V 3 0.062 1.6 190240 2427 60 28 2430 1013
O 3 0.062 1.6 200240 2528 65 31 2430 1013
c0.75c 19.0 F 4 0.094 2.4 360380 2630 60 28 1825 811
H,V 46 0.062 1.6 260310 2529 70 33 2430 1013
O 10 0.062 1.6 275310 2529 85 40 2430 1013
a. F = flat; V = vertical; H = horizontal; O = overhead.
b. Nozzle ID = 5/8 to 3/4 in. (15.9 to 19 mm),
c. For thickness of 0.75 in. (19 mm) and larger, double-bevel joint with a 50 degree minimum groove angle and 0.09 to 0.13 in. (2.3 to 3.3 mm) root face
is sometimes used.
18
 Typical Procedures for Flat Position Gas Metal Arc Welding Groove Welds
in Aluminum Alloys with Large Diameter Electrodes
Section Joint Geometry Welding
Thickness, Electrode Arc Current,
T F Diameter Shielding Weld Voltage, (DCEP), Travel Speed
in. mm Typea Degrees in. mm in. mm Gas Passb V Ac in./min mm/s
0.75 19.0 A 90 0.25 6.3 0.156 4.0 Ar 1 28 450 16 6.8
2 500
1.00 25.4 A 90 0.13 3.3 0.188 4.8 Ar 1,2 26.5 500 12 5.1
1.25 31.8 A 70 0.18 4.6 0.188 4.8 Ar 1,2 26.5 550 10 4.2
1.25 31.8 B 45 0.25 6.3 0.156 4.0 Ar 1 25 500 10 4.2
2 27 10 4.2
Back 26 12 5.1
1.50 38.1 A 70 0.18 4.6 0.188 4.8 Ar 1 26 550 10 4.2
2 27 575
3,4 29 600
1.50 38.1 A 70 0.18 4.6 0.219 5.56 Ar 1 27 650 8 3.4
2 27.5 675
1.75 44.5 A 70 0.13 3.3 0.219 5.56 Ar 1,2 26 650 10 4.2
3,4 27 600
1.75 44.5 B 45 0.25 6.3 0.188 4.8 Ar 1,2 28 600 10 4.2
3,4 30 550 14 5.9
Back 30 550 10 4.2
a. The joint types shown on page 21 are referred to by letter in the indicated column under joint geometry.
b. All passes are welded in the flat position, odd numbers from one side and even numbers from the other side with joint designs (A) and (C). Joint is
backgouged prior to depositing the back weld.
c. Constant current dc power source and constant-speed electrode drive unit.
19
 Typical Procedures for Flat Position Gas Metal Arc Welding Groove Welds
in Aluminum Alloys with Large Diameter Electrodes (Continued)
Section Joint Geometry
Thickness, Electrode Welding
T F Diameter Arc Current, Travel Speed
Shielding Weld Voltage, (DCEP),
in. mm Typea Degrees in. mm in. mm Gas Passb V A c in./min mm/s
2.00 50.8 A 70 0.2 4.6 0.188 4.8 He 1,2,3,4 32 550 10 4.2
2.00 50.8 B 45 0.3 6.3 0.188 4.8 Ar 1.2 28 600 10 4.2
37 26 500 14 5.9
Back 28 550 10 4.2
3.00 76.2 A 70 0.18 4.6 0.219 5.56 Ar-25%He 1,2 25 650 9 3.8
3,4 23 500 10 4.2
5,6 26 650 9 3.8
710 27 625 9 3.8
3.00 76.2 C 30 0.50 12.7 0.219 5.56 He 1,2 29 650 10 4.2
36 31
a. The joint types shown on page 21 are referred to by letter in the indicated column under joint geometry.
b. All passes are welded in the flat position, odd numbers from one side and even numbers from the other side with joint designs (A) and (C). Joint is
backgouged prior to depositing the back weld.
c. Constant current dc power source and constant-speed electrode drive unit.

20


Joint Geometry Types

21
 Typical Procedures for Gas Metal Arc Welding of Fillet Welds in
Aluminum Alloys with Large Diameter Electrodes and Argon Shielding
Electrode
Fillet Size Diameter Welding Travel Speed
Current, Arc Voltage,
in. mm in. mm Weld Passa Ab V in./min mm/s
0.50 12.7 0.156 4.0 1 525 22 12 5.1
0.50 12.7 0.188 4.8 1 550 25 12 5.1
0.63 16.0 0.156 4.0 1 525 22 10 4.2
0.75 19.0 0.156 4.0 1 600 25 10 4.2
0.75 19.0 0.188 4.8 1 625 27 8 3.4
1 25.4 0.156 4.0 1 600 25 12 5.1
2,3 555 24 10 4.2
1 25.4 0.188 4.8 1 625 27 8 3.4
2,3 550 28 12 5.1
1.25 31.8 0.156 4.0 1,2,3 600 25 10 4.2
1.25 31.8 0.188 4.8 1 625 27 8 3.4
2,3 600 28 10 4.2
a. Welded in the flat position with one or three passes, using stringer beads.
b. Constant-current power source and constant-speed electrode wire drive unit.

22
 Aluminum Welding Wire
Feet
Approximate
Fraction Decimal Millimeters per lb. per kg Wire Gauge

0.23 0.6 2083 4592 23

.030 0.8 1215 2678 20-1/2
.035 0.9 900 1984 19
.040 1.0 704 1552 18
3/64 .047 1.2 520 1146 17
.059 1.5 308 679 15
1/16 .062 1.6 290 639 14
.079 2.0 172 379 12
3/32 .093 2.4 130 287 11
1/8 .125 3.2 70 154 8
5/32 .156 4.0 45 99 6-1/2
3/16 .187 4.7 31 68 4-1/2
1/4 .250 6.3 20 44 2

23
 Preparation of Aluminum for Welding
Storage of Base Metal. Base metal should
be stored inside in a dry room, and covered to
prevent a buildup of shop dust.
Storage of Consumables. Aluminum rods
and coils of filler metal should be stored indoors
in a dry room, and ideally should be kept warm.
Once the package is opened, the filler metal
should be stored in an oven to avoid moisture
buildup on the metal surface. A storage tem-
perature of 100F (40C) is adequate, but the
manufacturers recommendation should be
consulted.
Plate Edge Preparation. Aluminum plate
edges can be prepared by any of the conven-
tional mechanical machining processes.
The plasma arc cutting process can be used
to make square edge or bevel cuts in aluminum.
24
When plasma cutting the 2XXX, 6XXX, or
7XXX series alloys, it may be necessary to
mechanically remove as much as 1/8 in.
(3.2 mm) from the plasma cut edge to eliminate
the crack-prone heat-affected zone. The series
1XXX, 3XXX, and 5XXX aluminum alloys are
not as crack sensitive and can usually be welded
as-cut.
Cleaning Prior to Welding. Several excel-
lent metal cleaners are available on the market,
and the metal fabricator should study the fea-
tures of each. After the cleaners have done their
job, the surfaces to be welded should be given a
final wipe with a clean cloth soaked in acetone.
Since acetone and similar cleaning agents are
highly flammable, care must be taken to avoid
exposing the fumes or open containers to a
source of ignition.
Compressed air, which may contain moisture or
oil from the compressor, should not be used to
blow off areas cleaned by solvents.
Oxide Removal with Wire Brushing.
Some fabricators have found it helpful to wire
brush the area to be welded after chemical clean-
ing and before the final wipe with acetone. This
should be done with a stainless steel wire brush
used only for brushing aluminum. The wire
brush is dedicated to brushing aluminum to
avoid bringing in impurities from other work
pieces. While brushing, the operator should be
careful to avoid smearing the surface of the alu-
minum and trapping impurities under the smears.
Shielding Gas Purity. Argon, helium, or
mixtures of the two can be used for gas metal
25
arc welding of aluminum. Shielding gas used
for welding aluminum should have a dew point
no higher than 70F (57C). Using shielding
gas with a higher dew point may result in poros-
ity in the weld.
For an expanded discussion of the shielding
gases to be used when arc welding aluminum, see
the AWS Handbook, Eighth edition, Volume 3.
A simple way to check for argon purity is to
strike a gas tungsten arc on a clean piece of
6061 aluminum. Holding the torch stationary,
form a puddle. If the puddle has a bright, silvery
appearance, the gas is pure enough for welding.
If a brown spot appears to be floating on the
puddle, there is a problem with gas purity. Note
that the argon may be of adequate purity, but the
shielding gas may pick up impurities because of
holes in the gas hose.
 Tips to Make the Aluminum Welding Job Easier
Use the proper welding power source. A
constant current unit is best for welding alu-
minum because it does not permit the high
current surges produced by constant voltage
machines. These surges cause arcing inside
the guide tube which results in deposits that
impede wire feed.
If the torch cables are more than 12 ft
(3.6 m) long, a push-pull wire feed system
should be considered.
Feed rolls with a U-groove rather than a
V-groove or knurled surface should be used.
Make sure that drive roll pressure isnt exces-
sive, because that will tend to distort the wire.
26
A straight barrel torch should be used rather
than a goose-neck torch to minimize friction
in the wire feed system.
Teflon or nylon wire feed conduits should be
used to reduce friction in the wire feed sys-
tem. When aluminum particles from the wire
feed rolls accumulate in the conduits, the
conduits should be replaced. Some users
report improved operation by blowing the
particles out using argon, but usually it is
best to replace the worn parts.
After a burnback, it is best to replace the
whole length of electrode in the conduit.
Otherwise, the slightest kink in the wire left
in the conduit may cause another jam.
 Troubleshooting

Problem Possible Cause Remedy

Porosity Contamination from dirt on plate or wire Clean base metal

Keep filler metal clean and dry

Contaminated shielding gas Shield weld area from drafts

Check hoses for leaks

Poor arc starting Bad workpiece connection Reconnect workpiece cable

Weld cracking Wrong filler metal See filler metal selection guide

Electrode burnback Insufficient wire feed Increase wire feed speed

Worn or dirty conduit liner Replace liner

Color mismatch after anodizing Use of 4XXX filler metal See filler metal selection guide

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 Basic Welding Symbols and Their Location Significance
Refer to AWS A2.4, Standard Symbols for Welding, Brazing, and Nondestructive Examination, for more information.

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Basic Welding Symbols and Their Location Significance (Continued)

29
Location of Elements of a Welding Symbol

30