Aluminium Extrusion and Component Welding

Aluminium Welding | Steel Welding | MIG and TIG welding

ABL has many years experience in welding both aluminium and steel components. Our welding capability is fully coded and we can handle aluminium extrusions, aluminium components, metal castings and steel requirements.

Welding has many advantages compared to other joining techniques, for example:

  • It is possible to weld materials of differing thicknesses – between 2mm and up to several centimetres thick.
  • Welding is one of the safest and easiest methods of creating airtight and watertight joints. This is especially important at ABL where we weld some of the components utilised in the manufacture of a range of designer radiators – Eskimo Designer Radiators.
  • ABL also has the capability to pressure test up to 7 psi bar to ensure integrity of the welded component.
  • Overall welding can be a cost effective method of joining materials.

The most common fusion welding methods are tungsten inert gas welding (TIG) and metal inert gas welding (MIG). Both these processes provide good results. The thickness of the parts to be welded determines the amount of filler required – fillers are standardised and are available as coiled wire or rods. Coiled wire is generally available in 1.2mm and 1.6mm diameters and is applicable only to MIG welding.

Rods are generally available in diameters ranging from 1.6mm to 6.4mm. Filler rod diameters cover a range of metal thicknesses from 0.7mm to 10.0mm.

During welding it is vital that the filler used is clean and dry and that the surface is cleaned prior to use to remove any contamination.

MIG Welding

MIG Welding has been developed from TIG welding to allow a speeding up of the welding process. The difference between MIG and TIG welding is that MIG welding utilises a filler welding wire as the electrode to create the arc instead of a tungsten tip. This method can be used to create all types of joints and all welding positions.

MIG welding is generally used for material thicknesses ranging from 3mm upwards.

The main advantage of this welding method is that it has a high welding speed and good penetration. The width of the heat affected zone is less than with any other welding process due to the speed of the process. Therefore welding deformation is less with MIG than it is with TIG welding.

However MIG welding is less successful when short weld runs are made or where the joints are not easily accessible. The inert gasses used for optimum performance by ABL when MIG welding consist of Argon and Helium.

TIG Welding

TIG Welding does not require flux because it also uses an inert gas shield to protect the weld pool from oxidisation. This makes the use of this welding method particularly suitable for aluminium welding.

It is used mainly for materials ranging from 2mm to 10mm thick and also for welding shorter joints. TIG welding can be carried out on all weldable aluminium alloys, and when controlled to the correct high standards it will produce the most fault free components of all conventional welding methods.