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Aluminum fillet joint penetration

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Squarewave technology made the transition through the zero amperage range faster than a regular sine wave, which improved arc starts and created a more stable arc. Now Miller introduces the next generation of technology with their new AC TIG inverter, which features three advanced Squarewave capabilities. First, it produces incredibly smooth, stable arcs because the Squarewave is driven through the zero point thousands of times faster than a rectifier-based welder. Second, inverter-based welders extend EN balance control. Making the EN portion of the cycle last longer: - Achieves greater penetration.
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Aluminum Welding

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TIG aluminium fillet welds - penetration - help! - Weld Talk Message Boards

Click here for Part 1. This second article on shape imperfections refers mostly to fillet welds but there are two additional butt weld imperfections that require some comment. Penetration becomes excessive when the joint gap is too large, the root faces are too small, the heat input to the joint is too high or a combination of these causes. The criteria which sets the level of acceptable penetration depends primarily on the application code or specification. BS Class 2 arc welding requires that the 'penetration bead shall not exceed 3mm for pipes up to and including mm bore or 6mm for pipes over mm bore'.
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Aluminiations(1): Shedding Light on Aluminum Welding Issues

Q: We tack weld many of our aluminum parts manually with gas metal arc welding GMAW in a fixture before final robotic welding takes place. We are having difficulty getting good fusion from the robot station in the areas where it welds over the tack weld. The aluminum material is T6, the manual tack weld wire is , and the robot welds with , all done with argon shielding gas. Any ideas how to resolve this?
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Affiliate Disclosure: This post may contain links that will earn us a commission at no cost to you. This helps keep Weldguru a free resource for our readers. Published on October 28, November 24, Aluminum is a lightweight, soft, low strength metal that can easily be cast, forged, machined, formed and welded. In many instances, aluminum is joined with the conventional equipment and techniques used with other metals.
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