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Spot Welding Aluminium

Spot Welding Aluminium

Spot Welding Aluminium

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

Not to sure about the quality of spot welds in aluminium alloys, try TOX stitching or blind riveting instead

Good Luck

RE: Spot Welding Aluminium

Hi there Spot guy,
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


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

Utility grade aluminum is quite soft to start with. Welding will further reduce the strength in the area of welding to approximately 60% of its nominal strength. If structural integrity of the joint is important, welding is not recommended. If it has to be welded, make sure you thoroughly test the joint after the welding.
Hope this helps,

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