Spot Welding Aluminium
Spot Welding Aluminium
(OP)
I have an application that required we fasten 0.040 Utility Grade Aluminium. We have a few differing opinions on whether it's a good idea to spot weld it or not. Are there any issues associated with this type of fastening??





RE: Spot Welding Aluminium
Good Luck
RE: Spot Welding Aluminium
Would it be possible for you to try it on a piece of the same material and conduct your own tests on it first?
TWWeld-good luck.
RE: Spot Welding Aluminium
Hello,
From my experience, the main problems in spot welding are: cracks, burning spots, incomplete fusion depending of the settings control, expulsion of fused metal.
When welding this thickness for aluminium alloy like 2024-T3 the suggested settings are:
- two electrode radius of 4" (with very well cooled electrodes)
- electrode force about 800 lbf (weld) and 2000lbf (forge)
- 42KA (weld current)
- 1 cycle of CO
- 1 cycle of HT
- 4 cycles of CD (current decay)
- 1 impulse
With this settings you will be able to have a good quality spot with a minimum shear strength of 435 lbf and a minimum spot diameter of 0.160".
Good luck and good welds!
RE: Spot Welding Aluminium
Hope this helps,
Efraim