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Tech Tip: What Are Your Aluminum Welds Telling You?

3/28/2018

63 Comments

 
Tech Tips
Pro Spot

Your Aluminum Welds are Telling You Something: Check the Gas!

How Gas Flow Affects Your Weld Results
When weld results are not as desired, we often at our welding equipment. More often than not, this can be an easy fix by adjusting your settings.

See below how gas flow can make a difference in your weld results.

Gas Flow High
If the Gas Flow is Too High, it will cause:
  • Spatter around the weld bead. It will also cause Inconsistency in the bead height due to the gas pressure being pushed into the bead.
Gas Flow Low
If the Gas Flow is Too Low, it will cause the weld to look:
  • Too Porous (If you look closely, you can see the porosity and the pin holes in the weld).
No Gas
No Gas Flow is nearly impossible to weld with, it causes:
  • Inconsistent Feed
  • Spatter
  • No Penetration
Incorrect Gas
Incorrect Gas can cause the weld to look like:
  • The welding wire is piercing through and cutting the material.
  • Little pellets dropping on the material.

Picture
For more Tech Tips and Videos, visit the ProSpot YouTube Channel and subscribe to stay updated!

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1/7/2019 07:13:26 pm

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10/19/2022 12:10:06 am

Thank you for pointing out that if the gas flow is too low, the weld would seem porous. My sister runs a steel furniture manufacturing facility. I'll send her this article and suggest she locate an industrial welding gas distributor so she can make sure her facility never runs out of gas.

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2/4/2023 04:01:44 am

I never took into account the fact that there would be inconsistency in the bead height when the gas pressure is pushed to the bead part, so it is best to spatter around it instead. I can imagine how having the right skills will definitely matter to get the best outcome for your project. And it is not just the tools and pieces of equipment that will make the project successful but the welder as well. Also, it will still be important to get quality materials from a welding supply distributor with a good reputation to ensure that the items will actually work together as well.

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3/28/2023 04:55:52 am

It's great that you talked about what your aluminum welds are telling you, proper gas flow is key to getting a proper finish in your aluminum welds. High gas flow causes spatter into the weld bead while low gas flow will create a porous result. The other day, my friend asked me about aluminum works, because he wanted to make an aluminum grill and asked me if I knew anything about it. Thanks to this article, I will surely tell him about aluminum welding and ask him to consult a well-known metal and welding company for more information about what he wants to be done.

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