1. Aluminum is very easy to oxidize in air and during welding, and the alumina (Al2O3) generated has a high melting point, is very stable, and is not easy to remove. Prevent the melting and fusion of the base metal, the ratio of oxide film is serious, it is not easy to surface the surface, and it is easy to generate slag inclusions, non-fusion, non-welding penetration and other deficiencies. The oxide film on the surface of aluminum and the adsorption of a large amount of water are easy to cause porosity in the weld. Before welding, chemical or mechanical methods should be used to strictly finish the appearance and remove the oxide film on the surface. Strengthen maintenance during the welding process to prevent oxidation. In the case of tungsten argon arc welding, the AC power supply is used to remove the oxide film through the "cathodic finishing" effect.
In gas welding, a flux is used to remove the oxide film. In the case of thick plate welding, the welding heat can be increased, for example, the helium arc heat is large, the use of helium or argon-helium mixed gas maintenance, or the selection of large standard MIGS maintenance welding, in the case of DC positive connection, there is no need for "cathodic finishing".
2. The thermal conductivity and specific heat capacity of aluminum and aluminum alloy are about twice that of carbon steel and low-alloy steel. The thermal conductivity of aluminum is more than ten times that of austenitic stainless steel. In the welding process, a large amount of heat can be quickly conducted to the inside of the base metal, so when welding aluminum and aluminum alloy, energy is consumed in addition to the molten metal pool, there is more heat wasted in other parts of the metal, the consumption of this useless energy is more obvious than the welding of steel, in order to obtain high-quality welded joints, energy gathering, power with high power should be selected as much as possible, and sometimes process methods such as preheating can also be selected.
3. The linear expansion coefficient of aluminum and aluminum alloy is about twice that of carbon steel and low-alloy steel. The volume shortening rate of aluminum condensation is large, and the deformation and stress of the weldment are large, so it is necessary to take measures to prevent welding deformation. When the molten pool of aluminum welding is condensed, shrinkage porosity, shrinkage porosity, thermal cracks and high internal stress are simply generated. In production, the method of adjusting the composition of the welding wire and the welding process can be used to prevent the occurrence of thermal cracks. If corrosion resistance allows, aluminum-silicon alloy welding wire can be used to weld aluminum alloys other than aluminum-magnesium alloys. When the aluminum-silicon alloy contains 0.5% silicon, the hot cracking tendency is larger, and with the addition of silicon content, the crystallization temperature scale of the alloy decreases, the fluidity improves significantly, the shortening rate decreases, and the hot cracking tendency decreases accordingly. According to the production experience, when the silicon content is 5%-6%, there is no hot cracking, so the selection of SAlSi strips (4.5%-6% silicon content) welding wire will have better crack resistance.
4. Aluminum has strong reflective ability of light and heat, and there is no obvious color change when solid and liquid are transformed, and it is difficult to judge during welding operation. The strength of high-temperature aluminum is very low, and it is difficult to support the molten pool, and it is easy to weld through.
5. Aluminum and aluminum alloy can dissolve a large amount of hydrogen in the liquid state, and almost do not dissolve hydrogen in the solid state. In the process of condensation and rapid cooling of the welding pool, the hydrogen does not have time to overflow, and it is easy to form hydrogen pores. The moisture in the arc column atmosphere, the welding material and the moisture adsorbed by the oxide film on the surface of the base metal are all important sources of hydrogen in the weld. Therefore, the origin of hydrogen should be strictly controlled to prevent the formation of pores.
6. Alloying elements are easy to transpirate and burn out, which reduces the function of the weld.
7. If the base metal is deformed and strengthened or solution aging, the welding heat will reduce the strength of the heat affected zone.
8. Aluminum is a face-centered cubic lattice, there are no allotropes, there is no phase change in the heating and cooling process, and the weld grains are easy to be coarse, and the grains cannot be refined through phase transformation.
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