Aluminum Welding
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Aluminum WeldingAluminum Welding
History and Testing of History and Testing of Aluminum WeldingAluminum Welding
Adam Robertson
Duke Schimmer
Euft Kruithof
December 10, 2006
ENGR 45, Santa Rosa Junior College, SRJC
HistoryHistory1827 - Friederich Wohler discovers aluminum
1892 - C.L. Coffin described the Gas Tungsten Arc Welding (GTAW) beginnings when a weld was made in non-oxidizing atmospheres
1939 - 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.
1946 - High Frequency stabilized AC tungsten-arc welding is used for aluminum alloys
1949 - US Navy uses inert-gas metal arc welding for aluminum hulls of 100 feet in length
More HistoryMore History
1969 - The Russian Welding program in Space began by producing Electron Beam welds, welding an AMG6 And DM-20 aluminum alloys with the Vulkan process.
1973 - The American Astronauts used Electron Beam welding process in June 1973, welding Aluminum Alloy 2219-T87.
1976 - The first welded aluminum sphere for a liquefied natural gas tanker was made.
1991 - 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.
IndustriesIndustries
• Aerospace• Automotive• Watercraft• Bicycle • Piping• Cable• Beverage• Marking
The Aluminum AdvantageThe 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
DisadvantagesDisadvantages
(In some applications)• Difficult to Form• Difficult to Weld• Dissipates Heat Quickly• Material is Expensive• Susceptible to Cyclic Wear• Brittle
Aluminum Welding TutorialAluminum 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 VideoWelding Theory Video
Video DemonstrationVideo Demonstration
PicturesPictures
PicturesPictures
Descriptions of TestsDescriptions 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 TestingHardness Testing
Hardness Testing ResultsHardness Testing ResultsRockwell B Hardness Testing
-10
-5
0
5
10
15
20
25
30
35
-1.750 -1.250 -0.750 -0.250 0.250 0.750 1.250 1.750
Distance From Weld, d, Inches
Har
dnes
s, R
B
Bend TestBend Test
Bend Test ResultsBend Test Results
Bend Test, Welded Aluminum vs. Solid Aluminum
0
5
10
15
20
25
30
0 100 200 300 400 500
Displacement, d, 1/1000 Inch
Forc
e, F
, lb.
Welded PlatesSolid Plate
Weld WeaknessWeld Weakness• The material weakness in welded metals is not
in the weld itself, but the area immediately surrounding it:
Weld Weakness – The MovieWeld Weakness – The Movie
Thanks for Watching!Thanks for Watching!
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