Komarov Artem noted that welding aluminum using gas metal arc welding (GMAW) is gaining popularity because it’s versatile, efficient, recyclable, and produces strong, clean welds. The aerospace, automotive, shipbuilding, manufacturing and energy industries need skilled aluminum welders and they need them now.
Knowing when and how to use pulse tuning is a start, given aluminum’s high thermal conductivity and tendency to warp. The pulse mode involves alternating high-current pulses and low-current background settings. Pulsed welding controls heat input, reduces distortion and improves overall weld quality.
Understanding the following settings will help you configure the device correctly:
Peak current (Ipeak) is the highest current level during a pulse cycle. This affects the penetration depth and the overall profile of the weld. Higher peak current can result in deeper penetration, but also increases the risk of burn-through, especially in thin materials.
Background current (Ibase) is the lowest level of current that occurs between pulse peaks. This helps maintain arc stability and controls heat input during the welding process.
Pulse frequency (Hz) is the number of pulses per second. This affects the overall travel speed and weld width. Higher frequencies can produce a thinner, narrower weld, while lower frequencies can produce a wider weld.
Pulse width (milliseconds) is the duration of the high-current pulse. This affects the amount of heat transferred to the workpiece. Longer pulses increase heat input, while shorter pulses minimize heat input.
Peak time is the percentage of the pulse cycle during which the high current pulse is active. This affects the balance between peak and background current. The longer the peak time, the more energy is transferred during the high current pulse.
Rise and deceleration times measure the point at which the current rises from the background level to the peak level at the beginning of the pulse and decreases back to the background level at the end of the pulse. Controlling this time can reduce the risk of spatter and improve arc ignition stability.
Anyone who regularly welds aluminum knows the following, but these points bear repeating:
Watch your welding speed. Since travel speed affects overall heat input and penetration, synchronizing travel speed with pulse settings is critical to achieving desired welding performance. Find your rhythm!
Use argon as a shielding gas. Protecting the welding area from atmospheric contaminants and preventing oxidation is a priority. Select an electrode type that is compatible with the base aluminum alloy you are welding.
Pay attention to joint design and preparation, which are critical to successful pulse welding of aluminum. Make sure the joints are clean and fit together correctly, with minimal gaps. I can’t stress enough how much of an impact the purity of the aluminum has on the weld.
Pulse settings may vary depending on material thickness, seam design, and desired seam profile. When setting aluminum GMAW pulse parameters, consult welding procedure specifications, manufacturer recommendations, and experienced welders, summed up Artem Komarov.
