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Aluminum Welding Guide
View technical guides for guidance on welding various metals and selecting the right Hobart Brothers filler metal solution for your application.
Aluminum Welding Guide
Problem Solving – Weld Bead Root Penetration And Fusion
Penetration and fusion are controlled by the welder, the weld joint design, the weld procedure, the welding equipment, and the shielding gas characteristics.
To Increase Root Penetration and Fusion:
- Increase welding amperage and reduce arc travel speed (while staying in front of the puddle). Decrease arc length and/or increase amperage to increase penetration.
- For better fusion, solvent clean and then wire brush base metal prior to fit-up to remove hydrocarbons and oxides. Fusion will not occur across an oxide barrier.
- Remove all edges that have been cut with a band saw.
For heat treatable aluminum alloys, remove all edges that have been cut by melting. Use stringer beads, do not weave. - Redesign the weld joint to improve access to the root, incorporate a 60° bevel to allow better penetration and wider fusion in the weld root.