ã€China Aluminum Network】 When it comes to aluminum profile welding, there are several important factors to consider in order to ensure a strong and high-quality weld. Here are the key points to keep in mind:
(1) Pre-Weld Preparation: It is essential to thoroughly clean the surface of the aluminum before welding. This can be done using either chemical or mechanical methods to remove oxide layers and any oils that may be present. For chemical cleaning, a 6% to 10% sodium hydroxide solution is used at around 70°C for about 0.5 minutes, followed by rinsing. Then, the part is immersed in a 15% nitric acid solution for one minute at room temperature to neutralize the surface, after which it is washed with warm water and dried. The cleaned surface should appear as a dull silver-white color. Mechanical cleaning can also be effective, using tools like pneumatic or electric grinders, scrapers, or even a 0.25mm copper brush for thin oxide layers. It's important to perform the welding immediately after cleaning; if not done within four hours, re-cleaning is necessary.
(2) Assembly Clearance and Tack Weld Spacing: Proper gap settings are crucial during assembly. If the gap is too small, it can cause overlapping of the plates during welding, leading to increased surface roughness and deformation. On the other hand, an overly large gap can make welding difficult and increase the risk of burn-through. Selecting the right clearance helps reduce warping. Based on experience, different joint thicknesses require specific process parameters, as outlined in Table 2.
(3) Choosing the Right Welding Equipment: Tungsten Inert Gas (TIG) welding is commonly recommended for aluminum due to its precision and control. This method uses an arc between the tungsten electrode and the workpiece, protected by argon gas. The alternating current allows for both direct and reverse polarity cycles, helping stabilize the arc and effectively remove oxide layers on the surface, resulting in a clean and well-formed weld.
(4) Filler Wire Selection: Typically, 301 pure aluminum wire or 311 aluminum-silicon wire is used depending on the application.
(5) Welding Technique and Parameters: The left-hand welding technique is generally preferred, with the torch held at a 60° angle to the workpiece. For thicker materials over 15mm, the right-hand technique is used, with the torch at a 90° angle. For wall thicknesses over 3mm, a V-groove with an included angle of 60° to 70° is recommended, with a gap no larger than 1mm. Multi-pass welding is required. For thinner sections under 1.5mm, no groove or filler wire is needed. When welding fixed pipe joints, such as a 200mm diameter pipe with 6mm wall thickness, a 3-4mm tungsten electrode, 220-240A current, and a 4mm filler wire with 1-2 passes are typically used.
By following these guidelines, you can achieve better results and ensure the structural integrity of your aluminum welds.
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