FRONIUS - ALU EDITION

TABLE OF CONTENTS

Introduction 4

Materials 6

Easy identification of alloys 9

Filler metals for aluminium welding 12

Processes 18

Special features of welding aluminium wires 20

Ignition comparison 24

SynchroPuls 25

Gases 27

Weld-seam preparation 30

Weld defects 33

Applications automobile industry 37

Except where expressly permitted, it is prohibited to pass on or duplicate this documentation or to

commercially exploit or communicate its contents. Any infringement herof shall render the
infringing party liable to the payment of damages. Text and illustrations technically correct at the
time of going to print.

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 INTRODUCTION
Discovered at the beginning of the 19th century, since 1880 as light metal in use. Produced
by electrolysis of aluminium oxide of alumina.

Areas of use
Utilisation of aluminium and its alloys instead of steel materials is becoming more and more
important. Aluminium is thus now found in fields such as:

• Aerospace
• Automotive industry (commercial and passenger vehicles)
• Shipbuilding
• Rail vehicle construction
As well in classical structural-steel fields such as:
• Hall construction
• Shelving construction
• Conservatory
• Windows etc.

Advantages of aluminium over steel

• Lower unit-weight (ρ=2,7kg/dm³) yet great strength (up to 450N/mm²)

• Resistant to climatic influences
• Good toughness at sub-zero temperatures
• Good to very good suitability for the production of continuous-cast profiles

The most important alloying constituents are:

• Magnesium Mg: 0,3 - 7% higher strength, finer granulation

• Mangan Mn: 0,3 - 1,2% better corr.resistance (salt water), higher strength

• Cupper Cu: -5% higher strength, less corr.resistance, important for hardenablility

• Silizium Si: -12% for casts, lowers the melting point down to 577°C

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 TYPES OF ALUMINIUM

Electricity industry Al 99,5 1...

• Wires for power lines

• Wires for transformers

• Cooling fins

Jewellery industry

• Decoration

• Motor-car-trims

Metal sheets, tubes AlMg 5...

• Tank construction, shipbuilding

• Dump through, apparatus

Profiles AlMgSi 6...

• Architecture, facades

• Windows, doors, fittings

• Car bodies

Castings AlSi 4...

• Gear boxes

• Engine blocks

• Cylinder head

• Aluminium rims for motor cars

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 MATERIALS
Categorisation

ALUMINIUM

Wrought Aluminium casting

aluminium alloys materials

age-hardenable non-age-hardenable age-hardenable non-age-hardenable

wrought alloys wrought alloys casting alloys casting alloys

AlMgSi AlMg G-AlMgSi G-AlSi

AlMg Mn

AlZnMg AlMnMg G-AlCuTi G-AlSiCu

G-AlCuTiMg

AlCuMg AlMn G-AlSiMg G-AlMg

AlZnMgCu

Pure Aluminium
It has high corrosion resistance, but low tensile strength (approx. 80N/mm²), which can be
increased by cold forming up to around 130N/mm². However, the effects of this cold strain
hardening are lost in the area of the weld-seam as a result of welding.
e.g. pure aluminium Al 99,9/Al 99,5
⇒ Experience: best attainable seam appereance, but lowest strength.

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Age-hardenable wrought alloys
By thermal treatment aluminium alloys with Magnesium and Silicium, zinc or cupper (e.g.
AlMgSi 1, AlZn 4,5 Mg1,...) can be hardened to approx. 450N/mm².
These materials are hardened by annealing (solution-annealing), then quenched and aged.
This leads to a strength-enhancing precipitation of the alloying elements in the aluminium
microstructure. Ageing can either be performed at room temperature over the course of
several days (cold ageing) or at temperatures of between 80°C and 160°C (warm ageing) in
a short period.
As a result of welding, hardened aluminium alloys lose their hardness in the heat-affected
zone. The greater the thermal input during welding, the more the heat of welding will reverse
the original hardening. Subsequent heat-treatment can give them back their original strength
values. The alloy AlNz 4,5Mg1 is worth mentioning here – this alloy can be restored to ist
original strength values after welding simply by being cold-aged.
⇒ Experience: If a steel construction should be replaced by Aluminium, age-hardenable
wrought alloys are mostly used.

Non-age-hardenable wrought alloys

Non-age-hardenable aluminium materials do not harden following heat treatment. They
derive their higher strength (as against pure aluminium) from solid-solution strengthening. By
alloying with magnesium and manganese, the tensile strength can be increased to around
280N/mm².
e.g. AlMg1/ AlMg3/ AlMg 4,5 Mn.
⇒ Experience: Used, if corrosion resistance is required (sea-water resistant) Metal sheets,
vehicle construction , checkered sheets.

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Alumium casting materials
Aluminium casting materials are obtained by additional alloying of the aluminium with silicon.
As a rule, only repair welding jobs are carried out with these casting alloys (electric arc
welding with special rod electrodes, TIG or MIG shielding gas welding). These repair welding
jobs are performed using filler metals of the same composition as the base metal, especially
where the welding location does not have any characterisitcs that differ from the cast grain
structure. Welding filler metals for these alloys may not have a high hydrogen content. After
polishing, the colour of the welding location is the same as that of the base metal. In general,
the weld seam will have a slightly different coloration after anodic axidation (anodisation).
This is particularly noticeable with Si filler materials.
⇒ Experience: Because of the low melting point, faster flowing out, a high welding speed
and clean seam appearance.

g
n
u Mg
g
e
n
ss
R

0 1 2 3 4 5 % Legierungsgehal

Cracking tendency of aluminium – dependend of Si- and Mg content

Attention: Mg-alloys prone to higher cracking sensitivity
use crater filling program!!

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 EASY IDENTIFICATION OF ALLOYS

Caustic solution check

(Separation of the alloy with copper, zinc, nickel and silicon)

Test solution I: Caustic soda solution 25%

Let one drop of the sample solution (l) affect 3 to 5 minutes long the bright
surface of the test piece, then wash it off with water and absorb the drop
with filter paper.

Al, AlMn, AlMg = no discoloration

Pure aluminium and alloys with Magnesium und Manganese remain
bright, the difference is recognizable by the surface hardness only.
(e.g. scratch cut with a scriber) No reaction means no Al-alloy, but
Magnesium.

G-AlMg Si = Mixture AlMg + Si = bright grey

AlCuMg, AlZnMg = black wipe offable

If the alloy contains copper, zinc or nickel, then a black mark remains

G-AlSi = grey not wipe offable

With a content of more than 3% silicon and the absence of the heavy
metals specified before, a grey mark occurs.

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Standardization
EN 573-1 (2)
z. B. material designation -1 (2)

EN AW 5082 A AlMg 4,5

European Aluminium material no. national norm (2) shows also the former norm
Norm semifinished i.e. Austria
product

Numbering structure according to DIN EN 573

EN AW = Aluminium wrought alloy
EN AC = Aluminium casting alloy (not as yet a valid EN number)

The designation system for aluminium wrought alloys has long been standardised
throughout the world by means of the international registration scheme.

The following example will help you with the ”translation”:

Designation to: DIN EN DIN 17007 ISO Internat. AA

Alloy reg.
1st example EN AW - 6060 / 3.3206 / 6060 / 6060 AA 6060
EN AW - AlMgSi AlMgSi 0,5 AlMgSi
2nd example EN AW - 6082 / 3.2315 / 6082 / 6082 AA ----
EN AW - AlSi 1 MgMn AlMgSi 1 AlSi 1 MgMn Not
standardised
in the US

1st figure: Alloy group DIN EN-AW

1 - Aluminium ≥ 99,0 % Naturally-hard
2 - Aluminium - copper - alloys Age-hardenable
3 - Aluminium - Mangan - alloys Naturally hard
4 - Aluminium - Silizium - alloys Naturally hard
5 - Aluminium - Magnesium - alloys Naturally hard
6 - Aluminium - Magnesium - Silizium - alloys Age-hardenable
7 - Aluminium - Zink - alloys Age-hardenable
8 - andere Aluminium - alloys

See DIN EN 573 for a more detailed explanation.

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Overview of comparable material designatins in various systems. (Composition is not
always exactly identical)
International F GB I
DIN-symbol (to Material n°. Internat. 1) ISO Symbol to Symbol to symbol
DIN 1700) (to DIN alloy Register NF A02-004 BS, BS-L, DT (convezionale) to
17007) (AA) (R 209) D 2) UNI 3)
Al 99,98R 3.0385 (1199) A-99 1
Al 99,8 2.0285 1080A Al 99,8 A-8 1A P-AlP 99,8
Al 99,7 3.0275 1070A Al 99,7 A-7 P-AlP 99,7
Al 99,5 3.0255 1050A Al 99,5 A-5 1B P-AlP 99,5
Al 99 3.0205 1200 Al 99 A-4 1C P-AlP 99,0
AlMn 3.0515 3103 Al-Mn 1 N3 P-AlMn 1,2
AlMnCu 3.0517 3003 Al-Mn 1 Cu A-M1
AlMn 0,5 Mg 0,5 3.0505 3105 N31
AlMn 1 Mg 0,5 3.0525 3005 A-MG0,5
AlMn 1 Mg 1 3.0526 3004 A-M1 G P-AlMn 1,2 Mg
AlMg 1 3.3315 5005 Al-Mg 1 A-G0,6 N41 P-AlMg 0,9
Al Mg 1,5 3.3316 (5050A) Al-Mg 1,5 A-G1,5 P-AlMg 1,5
Al Mg 2,5 3.3524 5052 Al-Mg 2,5 5052 P-AlMg 2,5
Al Mg 3 3.3535 5754 Al-Mg 3 A-G3M (P-AlMg 3,5)
AlMg 4,5 3.3345 5082 Al-Mg 4 P-AlMg 4,4
AlMg 5 3.3355 5056A Al-Mg 5 N6 P-AlMg 5
AlMg 2 Mn 0,3 3.3525 5221 Al-Mg 2 A-G2M N4
AlMg 2 Mn 0,8 3.3527 A-G2,5MC
AlMg 2,7 Mn 3.3537 5454 Al-Mg 3 Mn A-G3MC N51
AlMg 4 Mn 3.3545 5086 A-G4MC N5/6
AlMg 4,5 Mn 3.3547 5083 AlMg 4,5 Mn A-G4,5MC N8
AlMgSi 0,5 3.3206 6060 Al-MgSi A-GS H9
AlMgSi 0,8 3.2316 (6005) A-SG0,5 H10 P-AlSi 0,5 Mg
AlMgSiCu 3.3214 6061 Al-Mg 1 SiCu A-GSUC H20 P-AlMg 1 SiCu
AlMgSi 1 3.2315 6082 Al-Si 1 Mg A-SGM0,7 H30 P-AlMgSi
AlMgSiPb 3.0615 (6262) A-SGPb P-AlSi 1 MgMn
AlCuBiPb 3.1645 2011 A-U5PbBi FC1
AlCuMgPb 3.1655 (2030) A-U4Pb P-AlCu 5,5 PbBi
AlCu 2,5 Mg 0,5 3.1305 2117 Al-Cu 2 Mg A-U2G 2L69
AlCuMg 1 3.1325 2017A Al-Cu 4 Mg A-U4G H14 P-AlCu 4 MgMn
AlCuMg 2 3.1355 2024 Al-Cu 4 Mg 1 A-U4G1 2L97/98 P-AlCu 4,5 MgMn
AlCuSiMn 3.1255 2014 Al-Cu 4 SiMg A-U4SG H15 P-AlCu4,4SiMnMg
AlZn 4,5 Mg 1 3.4335 7020 A-Z5G P-AlZn 5 Mg
AlZnMgCu 0,5 3.4345 (7079) A-Z4GU
AlZnMgCu 1,5 3.4365 7075 Al-Zn 6 MgCu A-Z5GU 2L95/96 P-AlZn 5,8 MgCu

1)
The International Alloy Register (International Regristration Record) is kept at the Aluminium Association (AA) in
Wahsington. Most Western European countries, together with Australia and Japan, are changing over their designations
for wrought materials to this system; France already has changed over (NF A 02-104). The 4-digit designations not
enclosed in brackets have an identical composition to DIN.
2)
In BS, the type of wrought product is indicated by a preceding code letter in the case of pure aluminium, and in the case
of alloys by a code letter inserted between “N” (non-hardenable) or “H” (hardenable) and the number: S = sheet; E =
extruded product; T = tube, drawn; F = forgings; G = wire. Example: S1C = sheet Al 99; HE30 = extruded profile from
AlMgSi1.
3)
In Italy an abbreviated mode of notation (“contressegno”) is also usual, in which the symbols for the chemical elements
are reduced to one letter: Al = A; Mn = M; Mg = G; Cu = C, Si = S; Zn = Z; Example: P-AlZn 5,8 Mg Cu wird P-A/ 5,8
GC (P- = wrought material).

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 FILLER METALS FOR ALUMINIUM WELDING

Al99.9 S-Al99.9
Al99.8
Al99.7
Al99.5 S-Al99.5 S-Al99.5
Al99 S-Al99.5Ti S-Al99.5Ti
AlMnCu S-Al99.5Ti S-Al99.5Ti S-AlSi5
S-AlMn S-AlMn
AlMg1 S-Al99.5Ti S-Al99.5Ti S-AlMg3 S-AlMg3
AlMg1.5 S-AlMg3 S-AlMg3
AlMg1.8
AlMg2.5
AlMg3 S-Al99.5Ti S-Al99.5Ti S-AlMg3 S-AlMg3 S-AlMg3
AlMg5 S-AlMg3 S-AlMg3
AlMg2.7Mn S-AlMg3 S-AlMg3 S-AlMg3 S-AlMg3 S-AlMg3 S-AlMg3
AlMg2Mn0.3
AlMg2Mn0.8
AlMg4Mn S-AlMg3 S-AlMg3 S-AlMg5 S-AlMg5 S-AlMg5 S-AlMg5 S-AlMg4.5Mn
AlMg4.5Mn S-AlMg4.5MnS-AlMg4.5Mn S-AlMg4.5Mn
AlMg4Mn S-AlMg3 S-AlMg3 S-AlMg3 S-AlMg3 S-AlMg3 S-AlMg3 S-AlMg5 S-AlSi5
AlMg4.5Mn A-AlSi5 A-AlSi5 A-AlSi5 S-AlMg5 S-AlMg4.5Mn S-AlMg3
AlZn4.5Mg1 S-AlMg5 S-AlMg5 S-AlMg5 S-AlMg5 S-AlMg5 S-AlMg5 S-AlMg4.5Mn S-AlMg4.5Mn S-AlMg4.5Mn
S-AlMg4.5MnS-AlMg4.5Mn S-AlMg4.5Mn S-AlMg5
Al99.9 Al99.5 AlMn AlMg1 AlMg3 AlMg2.7Mn AlMg4Mn AlMgSi0.5 AlZn4.5Mg1
Al99.8 Al99 AlMnCu AlMg1.5 AlMg5 AlMg2Mn0.3 AlMg4.5Mn AlMgSi1.0
Base material Al99.7 AlMg1.8 AlMg2Mn0.8
AlMg2.5

Filler metal Available diameter Base materials

designation MIG TIG DIN-designation
SG - Al 99,5 0,8mm Al 99,5
DIN 1732 1,0mm 2,0mm Al 99
W.Nr. 3.0259 1,2mm 3,0mm Al 99,8
AWS ER 1100 1,6mm Al 99,7
AlMg 5, AlMg 3, AlMgMn, AlZnMg 1
SG - AlMg 5 0,8mm Cast alloys with Magnesium as main
DIN 1732 1,0mm 2,0mm alloying-constituent.
W.Nr. 3.3556 1,2mm 3,0mm G-AlMg 3, G-AlMg 3 Si, G-AlMg 5, G-AlMg
AWS ER 5356 1,6mm 5 Si, G-AlMg 10, G-AlMg 3 (Cu), AlMgSi 1
AlSi 5, AlMgSi 0,5; AlMgSi 0,8; AlMgSi 1
SG - AlSi 5 0,8mm Pure aluminium and Al-alloys with less than
DIN 1732 1,0mm 2,0mm 2 Gew.-% as main alloying-constituent.
W.Nr. 3.2245 1,2mm 3,0mm Al-cast alloys up to ~7% Si
AWS ER 4043 1,6mm

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Basically all weldable aluminum base materials can be processed with above alloys. For the
correct selection of the filler metal it is important to choose always an type-same alloy. Note:
while the following treatment of the workpiece never work with silicium alloy filler wire , since
otherwise the welding seams become darkly discoloured!

The choice of the filler metal will depend on the type of base metal, having regard to the
mechanical and chemical stresses to be expected.

Filler metal Base metal

Al 99,5 Ti Al 99,8
Al 99,5
AlMn
AlMg 5 Al 99,5
AlMg 4,5 Mn
AlMg 3
AlMg 5
AlMgSi 1
AlZn 4,5 Mg
AlCuMg
AlSi 5 AlMgSi 1
AlZn 4,5 Mg
AlCuMg
G-AlSiMg
G-AlSiCu
AlSi 12 G-AlSi 12
G-AlSiMg
G-AlSiCu

Consider the price differences between 1,0 and 1,2mm wire electrodes compared to 1,6mm.
With high-quality pulse power sources you can change over to the next larger diameter.
Furthermore thicker wires can be fed more easily!

Wire Ø1,2mm offers 44% more volume than Ø1,0

• Oxidation area
• Less pollution of the surface

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Treatment of the wire:
• Store at room temperature
• May not be older than one year
• Pack hermetically after weld end. (Advice: Add silicat gel or rice to prevent moisture
absorption)
• Protect against contamination

By these measures you reduce the absorption of hydrogen (pores, hot cracks, ageing,
hardness) and thus you increase the quality of your weld.

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Weldability

Material-specific peculiarities
The welding of Aluminium is fundamentally different from that of steel. The melting
temperature of steel is around 1500°C, that of aluminium around 660°C and that of Al-alloys
around 550-660°C.
• Al 99,5 658 - 659°C (almost melting point) the pores can not degas in time.
• AlMg 4,5Mn 575 - 640°C (longer solidification range) the longer time period enables the
pores to degas better.
• The thermal conductivity is four times as high, necessitating high thermal input during
welding.
• Because the thermal expansion is around twice as large, increased tension and distortion
occur in the work piece.
Another problem that must be taken into account is the high-melting oxide layer (fusion
temperature around 2040°C) which envelops the weldment and impedes welding.

Aluminium can not become brittle, or harden in the heat-affected zone. On the contrary – a
loss of strength may be expected on cold-strain hardened and age-hardenable alloys.

Pure aluminium (Al 99,9; Al 99,5; usw) Good weldability

Naturally hard alloys (AlMg- und AlSi-Alloys) Good weldability
Age-hardenable alloys (AlMgSi und AlZnMg) Good weldability
AlCu (approx. 6 % Cu and Zr) AlCuMg and AlZnMgCu Only limited suitability
(approx. 1,4 - 3,0 % Cu hot cracking)

Casting alloys are weldable, depending upon any casting defetcts (except for die-casting).

Physical characteristics:
Material abbreviation Electr. conductivity Thermal conductivity Solidification range
at 20°C at 20°C °C
S m/mm² W/cm K
Al 99,5 33,5...35,5 2,26...2,29 659...658
AlMg 5 14,0...19,0 1,20...1,34 625...590
AlMg 4,5Mn 15,0...19,0 1,20...1,30 640...575
AlMgSi 0,5 26,0...35,0 2,00...2,40 650...615
AlMg 1 SiCu 23,0...26,0 1,63 640...595
AlZn 4,5 Mg 1 21,0...25,0 1,54...1,67 655...610
G-AlSi 12 17,0...26,0 1,30...1,90 580...570
G-AlSi 10 Mg 17,0...26,0 1,30...1,90 600...550

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 Influence of the electrical conductivity of different wire electrode-alloys on the seam
geometry:

1 = SG-AlMg 5 2 = SG-AlSi 5 3 = SG-Al99,5 Ti

Trial:
At continuous
- Wire speed
- Welding speed
- Power source settings

Filler metal has been

changed.

Electr. conductivity Sm*)/mm² 15...19 24...32 34...36

Welding amperage**) A 250 300 340
Welding voltage V 26 28 29

1 Sm = 1/p p= resistivity Ω/mm²

i.e.: The higher Sm, the better the current transfer in the material.

Result:
The penetration profile depends very much on the used filler metal!!

*) Siemens
**) The modifications of the amperage arise as a result of the different electrical conductivity of the filler metal alloys.

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Physical characteristics
a.) The expansion coefficient is twice as big as with steel. This means strong warpage and
high internal stresses:
Counter measures:
• Observing the welding sequence
• The choice of weld process
• Transverse shrinkage should be possible
b.) The thermal conductivity is 4 times as great as on steel. There is a risk of fusion defects
on thick sheets, and of gas inclusions in the melt. Attention should also be paid to the
quenching behaviour of AlZn 4,5 Mg 1.
Counter measures:
• Pre-heating
• Increasing the heat input
• Torch position

Influence of the oxide layer

The oxid layer (Al2O3) can cause fusion defects, leads to notch-action of flushed-in oxide
particles and favours the formation of pores.
Counter measures:
• Mechanical removal of the oxide layer (grinding, brushing, scraping)
• Chemical removal (pickling)
• Cleansing action of the arc (positive polarity)
• Fluxes (gas-, electrodes- or submerged-arc powder, solders etc.)
• Deburring sheets

NOTE:
The weld process influences the heat input, the cleansing action of the arc (AC) and the
energy concentration.

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 PROCESSES

The decision as to which weld process to use for aluminium welding will be influenced by
following factors:
• Quality requirements
• Cost effectiveness
• Welding position
• Type of workpiece
• Thickness of material

MIG-welding
In this case, it is mainly the pulsed-arc technique that is used. Where the parameters have
been correctly selected, exactly one droplet of filler metal per pulse is detached from the wire
electrode. The result is virtually spatter-free welding.

Investigations have shown that for different filler metals and shielding gases, differentiated
pulse-forms greatly improve the welding result. Particularly in the field of aluminium, where
the thicknesses of the material are becoming ever smaller, the central requirement made of
the power source is that it should deliver a very steady arc at the lower end of the power
range. (approx. 30A). It is just important here to be able to set a low background current as it
is to have a fast-responding arc-length regulation facility, i.e. when the wire stick-out length is
changed, the length of the arc must remain constant.

2 3 2 3
IKrit
IM

1 4 1 4
t

1 2 3 4 1 2 3 4

Variable pulse form

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 x
x
x

Arc-length regulation

Advantages:
• Small material-thicknesses can be welded (0,8 mm)
• Wires of bigger diameter can be used (better wirefeed characteristic)
• Good positional weldability
• Low heat input
• Low warpage
• Fully mechanisable

Disadvantages:
• Higher incidence of porosity
• With larger thickness of material, through-welding in PA (gravity) position tends
to be difficult without weld-pool backup
• Welding over tacks can lead to welding defects

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 SPECIAL FEATURES OF WELDING ALUMINIUM WIRES

Torch equipment

• For the processing of soft aluminum wires, torches with plastic innerliner or teflon
innerliner and appropriate innerliner inserts are necessary in the torch neck.
• For aluminium wires, contact tubes of the next larger diameter must be used.
• For pure aluminium or Si-alloyed wires, push-pull systems are advantageous

Wirefeed:
Compared to steel wires, aluminium wires are very soft. This makes very special demands of
the wirefeed arrangements, which must be friction-free.

A four-roller drive with suitable feed rollers, will apply sufficient force to the wire that is to be
fed even at low contact pressures. In most cases, smooth, polished semicircular-grooved
rollers are used.

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⇒ Advice for the pressure adjustment of contact pressure rolls
Set more pressure on to the front conact pressure rolls than to the back ones.
If you stop the wire manually, the rolls should slip through!
The skip measure of the wire should not remain below 800mm.

NOTE:
If less than 800mm
- Friction of wire-guid insert liner too much (F2 motor current load test)
- Friction inside the drive rolls too much
- Friction inside the contatct tube too much
or
- Drive rolls are running offset
- Too much contact pressure on the contact pressure rolls, thus deformation of the wire.

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 Start and end of welding in aluminium welding

Is

150%

100%

50%

Start- SOLL Endkrater-

Strom Schweißstrom Strom

0 t

Welding program for preventing lack of fusion in aluminium at

the beginning of the seam

Aluminium not only has low density, but it is also a good thermal conductor. Due to this fact
cold-shuts at the start of welding are taking place. To counteract this, a function supported
by the power source delivers higher welding power at the start of the weld. In this way, the
base metal starts to be melted even during the ignition period. Once sufficient heat has been
inputted into the weld pool, the power is reduced to the nominal welding power. When the
heat runs ahead towards the end of the seam and there is a risk of ”drop-through”, the
welding power is reduced again, to a lower ”crater-fill” current.

⇒ Experience: Start/end settings depend on the thickness of the sheet metal.

I-S 135% with a slope time of 1.0 seconds and IE 50% worked satisfactorily as an universal
parameter.

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Ignition problems:
During the ignition period a short-circuit occurs. In the case of a conventional ignition now
the amperage can rise on up to 700 A during this short-circuit.
Due to this high amperage, the short-circuit becomes like an explosion resolved.
The result are spatters in the start area of the weld. This can be prevented with the option
Spatter Free Ignition (SFI).

Advantages of a conventional ignition

• No push-pull drive necessary
• When good ignition short starting times
Disadvantages:
• No reproduceable ignition
• Spatter ejection
• The thicker the wire, the higher the start current.
• Enormous contact tube load due to high start current (highest current
during the entire process); reduced contact tube life time
The power source must be able to supply the current necessary for breaking a short
circuiting bridge open. This current is generally higher than the pulse current!

OPTION SPATTER FREE IGNITION.

The option Spatter Free Ignition (SFI) enables a spatter-free ignition of the arc.
At the beginning of welding the wire is fed slowly towards the workpiece surface and is
stopped at the moment of contact.
Afterwards the welding current is activated and the wire is retracted.
If the correct arc length is achieved, the wire will be fed with the designated wire speed
necessary for the actual welding process.

To activate the option SFI proceed as following:

- SFI (Parameter Fdc - creeping) select in the Setup-Menue
- get out of the Setup-Menue
- select weld program

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 Remark! The release of the option Spatter Free Ignition is at present possible ex work
only. For the present only aluminium wires of 1,0 mm, 1,2 mm and 1,6 mm
and Fronius Push-Pull wire feed systems (Robacta Drive and Pull-MIG) are
supported.

Advantages of Spatter Free Ignition

• Basically spatter-free ignition
• Less stress on the contact tube caused by the start current (increased
contact tube life)
• 100% reproducible ignition
• Even with thicker wire trouble-free ignition
• By push-pull-drive improved wire feeding
• The max. short-circuit current which has to be supplied by the power source,
might be smaller than the pulse current.
Ignition comparison

conventional Spatter Free Ignition

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 OPTION SYNCHRO PULS

The option SynchroPuls is recommended for welded joints with Aluminiumalloys, whose
welding seams should show a ripple pattern. (particularly within the mechanized and
automated area).

Mode of operation:
The option SynchroPuls describes a pulsed arc, which changes between two power points of
a synergic line.
The two points of power result from the modification of the wire feed speed
(vD), to the certain extent of the value dFd (0 to 2m/min) adjusted in the set-up menue.
Example:
vD = 10,0 m/min and => Point of power 1: = 8,5 m/min
dFd = 1,5 m/min Point of power 2: = 11,5 m/min

The frequency F (0.5 to 5 cycles per second) determines, how many times it changes
between the points of power; it is also indicated in the set-up menue.
Is the frequency set F = 0, the option SynchroPuls is switched off.

The arc length correction for the lower point of power takes place by means of the parameter
arc length correction (e.g. on the Jobmaster torch, feeder, remote control, ...)
Whereas the arc length correction for the upper point of power has to be set in the set-up
menue, using the parameter „Arl“.

The following diagram shows the mode of operation of SynchroPuls, using „start of welding
aluminium“ (I-S = start current, SL =slope, I-E =end current):

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1
press and hold the torch switch
2  release the torch switch

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 GASES FOR ALUMINIUM WELDING

Pure argon delivers a quiet, steady metal transfer, but is inferior to argo-helium mixtures in
terms of penetration intensity and safety from hydrogen-induced porosity. Argon-helium
mixtures with helium components of between 30 and 70% have proved most advantageous.
The most widely used mixture is one consisting of 50% helium and 50% argon.
The higher the helium-component, the higher the arc voltage that is needed for the same arc
length.

In recent years, shielding gases with =2 (oxygen) and N2 (nitrogen) admixtures in the Vpm
(ppm) range have also been on the market. The only advantage of these shielding gases is
their quiet arc.
O2 and N2- admixtures do not improve the penetration behaviour, nor do they make the weld
seam any less susceptible to pore-formation.

Protection gases:
Argon: (l 1 according DIN 32 526 resp. EN 439) is the standard shielding gas for
general welding jobs.
Argon 70/He 30: (l 3 according DIN 32 526 resp. EN 439) for applications, where advanced
requirements concerning the porosity behaviour are asked for, further for
pure aluminium and larger wall thicknesses.
Argon 50/ He 50: (l 3 according DIN 32 526 resp. EN 439) Used if very high demands
concerning freedom of porosity are given, particularly with pure
aluminum, e.g. Al 99.5 or Al 99.8 or larger wall thicknesses.

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Gas consumption (in relation to argon):
• Short arc 12 - 15 l/min
• Spray- and pulsed arc 15 - 20 l/min

Following is valid for mixed gases:

Shielding gas Correction factor*) Minimum amount
Ar 70/ He 30 1,17 20 l/min
Ar 50/ He 50 1,35 28 l/min
Ar 30/ He 70 1,70 35 l/min

Increased helium content facilitates the outgassing (higher thermal input).

The purity and mixing accuracies correspond to DIN 32 526 resp. EN 439.
The gases are applicable for all types of arc and power ranges. Other welding shielding
gases are available on request.

*) read off gas amount x correction factor = actual flow rate

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Penetration form
The higher helium content, the wider (and thus flatter) the seam. The penetration is no longer
„finger-shaped“ as it is with argon, but becomes rounder and deeper. The more favourable
penetration behaviour makes it easier to be sure of achieving through-welding in the root
zone, and permits higher welding speeds.

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 WELD-SEAM PREPARATION

Working
The very greatest cleanliness is required in the working and welding of the seam, as
otherwise ist corrosion resitance may be impaired and it will tend to form pores. Work with
aluminium should take place completely separately from work with steel.

Tools that have been used for steel must not be used for aluminium. Aluminium should be
worked and stored in a dust-free, dry and splashwater-free environment. Clean clothing and
gloves are also necessary.

Aluminium is highly sensitive to notch impact (even when under static loading) and should
thus not be scribed with a sharp scribing tool or stamped with a makring punch. Usually, a
pencil is used for tracing. It is possible to straighten aluminium by pressing, hammering or
flame-straightening – still following the above rules, however. Moreover, flame-straightening
should only be carried out after consultation with the manufacturer. All these points also
particularly apply to the weld-seam preparation. If there is not to be a root gap, the root
penetration side should be chamfered.

In open-root welding, the oxide inclusions collect in the middle. Subsequent root-pass
chipping and capping, or a weld-pool back-up, are helpful measures here.

⇒ Experience: Brush the seam area first (CrNi-brush) and/or degreasing (Aceton-alcohol)

Weld shapes
The shape of the weld will be largely dictated by the thickness of the material and the design
of the weldment. For fully mechanised welding, extruded profiles with an integrated pool
backing support are usual. For water-tight Y- or U-welds, the root pass should be TIG-
welded, and the rest MIG-welded.

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 Thickness of Groove Wire Ø Weld current Welding speed Argon- Number of
material mm shape mm A cm/min consumption layers
l/min
2 II 0,8 110 80 12 1
3 II 1,0 130 75 12 1
4 II 1,2 160 70 15 1
5 II 1,2 180 70 15 1
6 II 1,6 200 65 15 1
8 V 1,6 240 60 16 2
10 V 1,6 260 60 16 2
12 V 1,6 280 55 18 2
16 V 1,6 300 50 20 3
20 V 1,6 320 50 20 3

Standards for manual welding:

The values become influenced by the type of inert gas, the material and the type of arc.

Adjusting advices:
Weld-seam preparation:
Wrong: Correct:

Root notches can be prevented by breaking the edges on the root side of the weld.

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Please consider the angle of Vee compared to steel!

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 WELD DEFECTS

Consequences of inadequate gas shielding

Insufficient shielding of the weld pool leads to reactions between the air and the weld pool,
and to porous welds with inadequate stability.

Fault:
Draugths (e.g. out on construction
sites) interfere with the shielding gas
coverage

Consequence:
Insufficient gas shielding, pore-
formation in the weld-seam

The main cause of pores in aluminium is the inclusion of hydrogen and nitrogen (from 0,5 %
N2 upwards => high sensitivity to porosity).

Sources of hydrogen:
• Damp or dirty weld region
• Damp or dirty filler metal
• Hydrogen in the filler metal
• Leaky torch system
• Blown-in air
• Unstable arc
• Damp shielding gas due to the use of the wrong quality of hose or to a leaky system.

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Fusion defects
Only the arc (not the weld-pool) has sufficient energy to fuse the groove face and create a
stable join.

Other influential criteria

• Heat input
• Electrical conductivity of the wire electrode
• Characteristic curve in the control response of the power source
• Type of arc
• Composition of shielding gas

To prevent fusion defects, the seam to be welded must be expertly prepared and worked.

Following mistakes can be made here:

Weld preparation angle is too small

Ccorrect: 60° to 70°

Root height too great

Root opening gap is too wide

Edge misalignment is too big

Overwelding of strongly reinforced beads

Correct: Before overwelding, weld the bottom bead so that
this is through-shaped

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 Attachment fusion defect when welding at low arc power,
attachment point not ground; not welded with sufficient
overlap.
Correct: grind end of seam, ignite before the end of the
seam and continue welding.

Fusion defects may occur, when the arc is prevented from reaching the weld edges or the
already-welded pass by the weld pool running ahead.

Welding speed is too low Welding in PG-position (vertical- Excessively ”pushing” torch angle.
or deposition rate is too high. Down). The deposition rate must
Do not weld over-thick beads! be limited. Do not weld too slowly!

If the torch position is incorrect, the arc fuses the weld-edges on one side only. This results
in fusion defects and thus unstable joins.

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The torch is not being held The torch is being inclined Faulty torch position caused by
over the middle. too much towards one weld edge. restricted accessibility

Oxide inclusions
A small quantity of oxides is necessary for the stability of the arc. However, too much will
cause oxide inclusions, which can become the starting points of cracks when subjected to
dynamic loading.

Cracks
In order to prevent hot crakcs, welding is usually performed with over-alloyed filler metals.
Crater cracks occur as a result of the large shrinkage dimension of aluminium. They can be
prevented by using a run-off plate or a crater-fill program (power source must be suitable for
such a program).

Clean seam preparation (deburring, degreasing) also helps to prevent cracking.

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 APPLICATIONS IN THE AUTOMOTIVE INDUSTRY
AUDI A2

AUDI A8

Bibliography:
DIN 17007
Deutscher Verband für Schweißtechnik (German Welding Society)
Gas-shielded metal arc welding
Linde publication: Gas-shielded arc welding of aluminium
Aluminium-Pocketbook: (Publisher: Düsseldorf Aluminium Center)
www.audi.de

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