1、1The EverydayPocket Handbookfor Gas Metal ArcWelding (GMAW)of AluminumCompiled as a useful tool foron-the-job welding personnel by theAWS Product Development CommitteeNumber 8 in a series2NOTE: Although care was taken in choosing and presenting the data in this guide, AWS cannot guarantee that it is
2、error free. Further, this guide is not intended to be an exhaustive treatment of the topic and therefore may not include allavailable information, including with respect to safety and health issues. By publishing this guide, AWS does not insureanyone using the information it contains against any lia
3、bility or injury to property or persons arising from that use.Edited byLee G. KvidahlIngalls Shipbuilding 1998 by American Welding Society. All rights reservedPrinted in the United States of America3Basic Safety Precautions .4Typical Joint Geometries for Arc Weldingof Aluminum.6Designations for Wrou
4、ght Alloy Groups 9Chemical Composition of Wrought AluminumFiller Metals10Typical Aluminum Filler Metal Properties(As-Welded Condition).11Guide to the Selection of Filler Metal for GeneralPurpose Welding.12Influence of Shielding Gas on Weld Profile15Typical Procedures for Gas Metal Arc Weldingof Groo
5、ve Welds in Aluminum Alloys withArgon Shielding16Typical Procedures for Gas Metal Arc Weldingof Fillet Welds in Aluminum Alloys withArgon Shielding18Typical Procedures for Flat Position Gas MetalArc Welding Groove Welds in AluminumAlloys with Large Diameter Electrodes19Joint Geometry Types . 21Typic
6、al Procedures for Gas Metal Arc Weldingof Fillet Welds in Aluminum Alloys withLarge Diameter Electrodes and ArgonShielding. 22Aluminum Welding Wire 23Preparation of Aluminum for Welding . 24Storage of Base Metal. 24Storage of Consumables . 24Plate Edge Preparation 24Cleaning Prior to Welding 24Oxide
7、 Removal with Wire Brushing. 25Shielding Gas Purity . 25Tips to Make the Aluminum Welding JobEasier 26Troubleshooting 27Basic Welding Symbols and Their LocationSignificance 28Location of Elements of a Welding Symbol. 30Other Publications Available from AWS 31Table of Contents4Burn Protection. Molten
8、 metal, sparks, slag,and hot work surfaces are produced by welding,cutting, and allied processes. These can causeburns if precautionary measures are not used.Workers should wear protective clothing madeof fire-resistant material. Pant cuffs, open pock-ets, or other places on clothing that can catcha
9、nd retain molten metal or sparks should not beworn. High-top shoes or leather leggings andfire-resistant gloves should be worn. Pant legsshould be worn over the outside of high-topshoes. Helmets or hand shields that provide pro-tection for the face, neck, and ears, and a headcovering to protect the
10、head should be used. Inaddition, appropriate eye protection should beused.Electrical Hazards. Electric shock can kill.However, it can be avoided. Live electrical partsshould not be touched. The manufacturersinstructions and recommended safe practicesshould be read and understood. Faulty installa-tio
11、n, improper grounding, and incorrect opera-tion and maintenance of electrical equipmentare all sources of danger.All electrical equipment and the workpieceshould be grounded. The workpiece lead isnot a ground lead. It is used only to completethe welding circuit. A separate connection isrequired to g
12、round the workpiece. The work-piece should not be mistaken for a groundconnection.Basic Safety Precautions5Fumes and Gases. Many welding, cutting,and allied processes produce fumes and gaseswhich may be harmful to health. Avoid breath-ing the air in the fume plume directly above thearc. Do not weld
13、in a confined area without aventilation system. Use point-of-welding fumeremoval when welding galvanized steel, zinc,lead, cadmium, chromium, manganese, brass, orbronze. Do not weld on piping or containersthat have held hazardous materials unless thecontainers have been inerted properly.Compressed G
14、as Cylinders. Keep caps oncylinders when not in use. Make sure that gascylinders are chained to a wall or other struc-tural support.Radiation. Arc welding may produce ultra-violet, infrared, or light radiation. Always wearprotective clothing and eye protection to pro-tect the skin and eyes from radi
15、ation. Shieldothers from light radiation from your weldingoperation.Refer to AWS/ANSI Z49.1, Safety in Welding,Cutting, and Allied Processes, for additionalinformation.6Typical Joint Geometries for Arc Welding of Aluminum (Not to Scale)7Typical Joint Geometries for Arc Welding of Aluminum (Continued
16、) (Not to Scale)8Typical Joint Geometries for Arc Welding of Aluminum (Continued)9Designations for Wrought Alloy GroupsA system of four-digit numerical designations is used to identify wrought aluminum alloys. The first digit indicates the alloy group as follows:Aluminum, 99.0% and greater 1XXX*Majo
17、r Alloying Element:Copper 2XXXManganese 3XXXSilicon 4XXXMagnesium 5XXXMagnesium and Silicon 6XXXZinc 7XXXOther elements 8XXXUnused series 9XXX*For 1XXX series, the last two digits indicate the minimum aluminum purity (e.g., 1060 is 99.60% Al minimum). The second digit in all groupsindicates consecut
18、ive modifications of an original alloy, such as 5154, 5254, 5454, and 5654 alloys.10Chemical Composition of Wrought Aluminum Filler MetalsFiller AlloyElements, wt. %aOther ElementsAlSi Fe Cu Mn Mg Cr Zn Ti Each Total1100 Note b Note b 0.050.20 0.05 0.10 0.05c0.15 99.0 min.01188 0.06 0.06 0.005 0.01
19、0.01 0.03 0.01 0.01c 99.88 min.2319 0.20 0.03 5.86.8 0.200.40 0.02 0.10 0.100.20 0.05c0.15 Remainder4009d4.55.5 0.20 1.01.5 0.10 0.450.60 0.10 0.100.20 0.05c0.15 Remainder4010e6.57.5 0.20 0.20 0.10 0.300.45 0.10 0.20 0.05c0.15 Remainder4011f6.57.5 0.20 0.20 0.10 0.450.70 0.10 0.040.20 0.05f0.15 Rema
20、inder4043 4.56.0 0.80 0.30 0.05 0.05 0.10 0.20 0.05c0.15 Remainder4047 11.013.0 0.80 0.30 0.15 0.10 0.20 0.05c0.15 Remainder4145 9.310.7 0.80 3.34.7 0.15 0.15 0.15 0.20 0.05c0.15 Remainder4643 3.64.6 0.80 0.10 0.05 0.100.30 0.10 0.15 0.05c0.15 Remainder5183 0.40 0.40 0.10 0.501.00 4.35.2 0.050.25 0.
21、25 0.15 0.05c0.15 Remainder5356 0.25 0.40 0.10 0.050.20 4.55.5 0.050.20 0.10 0.060.20 0.05c0.15 Remainder5554 0.25 0.40 0.10 0.501.00 2.43.0 0.050.20 0.25 0.050.20 0.05c0.15 Remainder5556 0.25 0.40 0.10 0.501.00 4.75.5 0.050.20 0.25 0.050.20 0.05c0.15 Remainder5654 Note g Note g 0.05 0.01 3.13.9 0.1
22、50.35 0.20 0.050.15 0.05c0.15 Remaindera. Single values are maximum, except where otherwise specified. e. Same composition as A356.0 cast alloy.b. Silicon plus iron shall not exceed 0.95 percent. f. Beryllium content is 0.04 to 0.07 percent. Same compositionc. Beryllium shall not exceed 0.0008 perce
23、nt. as A357.0 cast alloy. Used for GTAW rod only.d. Same composition as C355.0 cast alloy. g. Silicon plus iron shall not exceed 0.45 percent.11Typical Aluminum Filler Metal Properties (As-Welded Condition)Filler AlloyMinimum Shear StrengthAll-Weld-MetalUltimate Tensile Strengthksi MPa ksi MPa1100 7
24、.5 52 13.5 932319 16.0 110 37.5 2584043 11.5 79 29.0 2005183 18.5 128 41.0 2835356 17.0 117 38.0 2625554 17.0 117 33.0 2305556 20.0 138 42.0 2905654 12.0 83 32.0 22112Guide to the Selection of Filler Metal for General Purpose Weldinga,b,cBase Metal201.0, 206.0, 224.6.319.0, 333.0, 354.0, 355.0, C355
25、.0.356.0, A356.0, 357.0, A357.0, 413.0, 443.0, A444.0.511.0, 512.0, 513.0, 514.0, 535.0.7004, 7005, 7039, 701.0, 712.0.6009, 6010, 6070.6005, 6061, 6063, 6101, 6151, 6201, 6351, 6951. 5456 54541060, 1070, 1080, 1350ER4145 ER4145 ER4043d,eER5356e,f,gER5356e,f,gER4045d,eER4043eER5356gER4043e,g1100, 30
26、03, Alc. 3003ER4145 ER4145 ER4043d,eER5356e,f,gER5356e,f,gER4043d,eER4043eER5356gER4043e,g2014, 2036 ER4145hER4145hER4145 ER4145 ER4145 2219 ER2319dER4145hER4145e,fER4043eER4043eER4043d,eER4043d,e ER4043e3004, Alc. 3004 ER4043eER4043eER5356iER5356iER4043eER4043e,iER5356gER5356i5005, 5050 ER4043eER40
27、43eER5356iER5356iER4043eER4043e,iER5356gER5356i5052, 5652l ER4043eER4043e,iER5356iER5356iER4043eER5356f,iER5356iER5356i5083 ER5356e,f,gER5356gER5183g ER5356gER5183gER5356g5086 ER5356e,f,gER5356gER5356g ER5356gER5356gER5356g5154, 5254l ER4043e,iER5356iER5356i ER5356iER5356iER5356ia. Service condition
28、s such as immersion in fresh or salt water, exposure to specific chemicals, or a sustained high temperature over 150F (66C) maylimit the choice of filler metals. Filler metals ER5183, ER5356, ER5556, and ER5654 are not recommended for sustained elevated-temperature service.b. Recommendations in this
29、 table apply to gas shielded arc welding processes. For oxyfuel gas welding, only ER1188, ER1100, ER4043, ER4047, andER4145 filler metals are ordinarily used.c. Where no filler metal is listed, the base metal combination is not recommended for welding.d. ER4145 may be used for some applications.e. E
30、R4047 may be used for some applications.f. ER4043 may be used for some applications.g. ER5183, ER5356, or ER5556 may be used.h.m. See table footnotes on next page. 13Guide to the Selection of Filler Metal for General Purpose Weldinga,b,c(Continued)Base Metal,5154,l5254l5086 5083,5052, l5652l5005,505
31、0,3004, Alc. 3004 22192014, 2036,1100, 3003, Alc. 30031060, 1070, 1080, 1350.1060, 1070, 1080, 1350ER5356e,f,gER5356gER5356gER4043e,gER1100e,fER4043e,gER4145e,fER4145 ER1100e,fER1188e,f,k,m1100, 3003, Alc. 3003ER5356e,f,gER5356gER5356gER4043e,gER1100e,fER4043e,gER4145e,fER4145 ER1100e,f2014, 2036 ER
32、4145 ER4145 ER4145hER4145h2219 ER4043e ER4043e,gER4043d,eER4043d,eER2319d 3004, Alc. 3004 ER5356iER5356gER5356gER5356e,f,iER5356f,iER5356f,i5005, 5050 ER5356iER5356gER5356gER5356e,f,gER5356f,i 5052, 5652lER5356iER5356gER5356gER5654f,i,l 5083 ER5356gER5356gER5183g 5086 ER5356gER5356g 5154, 5254lER565
33、4i,l a.g. See table footnotes on preceding page.h. ER2319 may be used for some applications. It can supply high strength when the weldment is postweld solution heat-treated and aged.i. ER5183, ER5356, ER5554, ER5556, and ER5654 may be used. In some cases, they provide: (1) improved color match after
34、 anodizing treatment,(2) highest weld ductility, and (3) higher weld strength. ER5554 is suitable for sustained elevated-temperature service.j. ER4643 will provide high strength in 1/2 in. (12.7 mm) and thicker groove welds in 6XXX alloys when postweld solution heat-treated and aged.k. Filler metal
35、with the same analysis as the base metal is sometimes used. Filler alloys ER4009 or R4009, ER4010 or R4010, and R4011 meet thechemical composition limits of R-C355.0, R-A356.0, and R-A357.0 alloys, respectively.l. Base metal alloys 5254 and 5652 are useful for hydrogen peroxide service. ER5654 fille
36、r metal is used for welding both alloys for low-temperatureservice 150F (66C) and below.m. ER1100 may be used for some applications.14Guide to the Selection of Filler Metal for General Purpose Weldinga,b,c(Continued)Base Metal201.0, 206.0, 224.6.319.0, 333.0, 354.0, 355.0, C355.0356.0, A356.0, 357.0
37、, A357.0, 413.0, 443.0, A444.0511.0, 512.0, 513.0, 514.0, 535.07004, 7005, 7039, 701.0, 712.06009, 6010,6070.6005, 6061, 6063, 6101, 6151, 6201, 6351, 6951. 5456 54545454 ER4043eER4043e,iER5356iER5356i ER4043eER5356f,iER5356iER5554h,i5456 ER5356e,f,g ER5356gER5556g ER5356gER5556g6005, 6061, 6063, 61
38、01, 6151, 6201, 6351, 6951ER4145 ER4145e,fER4043e,i,jER5356iER5356e,f,iER4043d,e,jER4043e,i,j6009, 6010, 6070 ER4145 ER4145e,fER4043d,e,jER4043eER4043eER4043e,i,j7004, 7005, 7039, 710.0, 712.0 ER4043eER4043e,iER5356iER5356g511.0, 512.0, 513.0, 514.0, 535.0 ER4043e,iER5356i356.0, A356.0, 357.0, A357.
39、0, 413.0, 443.0, A444.0ER4145 ER4145e,fER4043e,k319.0, 333.0, 354.0, 355.0, C355.0ER4145hER4145e,f,k201.0, 206.0, 224.0 ER2319d,ka.m. See table footnotes on previous page.15DIRECT CURRENT ELECTRODE POSITIVE (DCEP)Influence of Shielding Gas on Weld Profile16Typical Procedures for Gas Metal Arc Weldin
40、g ofGroove Welds in Aluminum Alloys with Argon ShieldingSection ThicknessWelding PositionaJoint Geom-etrybRoot Opening No. of Weld PassesElectrode DiameterWelding Current (DCEP), AArcVolt-age,VShielding Gas Flow RatecTravel Speedin. mm in. mm in. mm ft3/h L/min in./min mm/s0.06 1.6 FFAG00.0902.41 .0
41、30 0.8 70110 1520 25 12 2545 10.519.00.09 2.4 FF,V,H,OAG00.1203.211.030.047.0300.81.20.89015011013018221823303014142545233010.519.09.712.70.12 3.2 F,V,HF,V,H,OAG0.090.192.44.611.030.047.030.0470.81.20.81.212015011013520241923303014142430182810.212.77.611.80.19 4.8 F,V,HF,V,HOF,VH,OBFFHH0.060.060.060
42、.090.190.191.61.61.62.44.84.821223.030.047.047.047.047.062.0470.81.21.21.21.21.61.213017514018014017514018513017522262327232723272327353560356016162816282430243024302430253510.312.710.312.710.312.710.312.710.514.80.25 6.4 FFV, HOF,VO,HBFFFHH0.090.090.090.090.120.250.252.42.42.42.43.36.46.4223F,1R3F,
43、1R2346.047.062.047.062.047.047.062.047.062.047.0621.21.61.21.61.21.21.61.21.61.21.617520018522516519018020017522517020024282429252925292529252940404560406019192128192824302430253525352430254010.312.710.312.710.514.810.514.810.312.710.516.9a. F = flat; V = vertical; H = horizontal; O = overhead.b. Re
44、fer to pages 68.c. Nozzle ID = 5/8 to 3/4 in. (15.9 to 19 mm).17Typical Procedures for Gas Metal Arc Welding ofGroove Welds in Aluminum Alloys with Argon Shielding (Continued)Section ThicknessWelding PositionaJoint Geom-etrybRoot Opening No. of Weld PassesElectrode DiameterWelding Current (DCEP), AA
45、rcVolt-age,VShielding Gas Flow RatecTravel Speedin. mm in. mm in. mm ft3/h L/min in./min mm/s0.38 9.6 FFV, HOF,VO,HC-90FFFHH0.090.090.090.090.250.380.382.42.42.42.46.49.69.61F,1R2F,1R3F,1R5F,1R4810.062.062.062.062.062.0621.61.61.61.61.61.62252902102751902202002502102901902602629262926292629262926295
46、050558050802424263824382030243524302540243025408.512.710.314.810.312.710.516.910.312.710.516.90.75 19.0 FFV, H , OFV, H , OC-60FFEE0.090.120.060.060.062.33.21.61.61.63F,1R4F,1R8F,1R3F,3R6F,6R.062.094.094.062.062.0621.62.42.41.61.61.63404003253752403002703302302802631263126312631263160608060802828382
47、838142016202430162416245.98.56.88.510.312.76.810.36.810.3a. F = flat; V = vertical; H = horizontal; O = overhead.b. Refer to pages 68.c. Nozzle ID = 5/8 to 3/4 in. (15.9 to 19 mm).18Typical Procedures for Gas Metal Arc Welding ofFillet Welds in Aluminum Alloys with Argon ShieldingSection ThicknessWe
48、lding aPositionaNo. of Weld PassesElectrode DiameterWelding Current (DCEP),AArcVoltage,VShielding Gas Flow RatebTravel Speedin. mm in. mm ft3/h L/min in./min mm/s0.094 2.4F,V,H,O1 0.030 0.8 100130 1822 30 14 2430 10130.125 3.2 FV, HO1110.0300.0470.0300.0300.0470.81.20.80.81.21251501101301151402024192320243030401414192430243024301013101310130.19 4.8 FV, HO1110.0470.0300.0470.0300.0471.20.81.20.81.218021013017513019022262125222630354514162124302
