Aluminum Welding of Railings, Cast, Frames – Aluminum Welder


JW Portable Welding & Repairs offers aluminum welding of aluminum railings, aluminum cast and aluminum frames. We offer aluminum welding services in Southern Ontario. Our aluminum welder setup offer a mobile setup that consists of stick aluminum welding, GTAW (Tig) aluminum welding and Mig aluminum welding. Certainly, each technique has its advantages and disadvantages. Aluminum welding performed outside in the open air could be challenging due to variety of reasons. High wind eliminates our gas shield. Uncomfortable position forces us to use more comfortable welding technique which could be less appropriate for your project. Unpredictable heat accumulation due to lack of information regarding thickness of the element being welded irreversible damage

Stick aluminum welding for repair of aluminum railings

Stick aluminum welding on site and in place for repair of aluminum railings requires no special attachments to our mobile welding unit. It is a perfect solution in windy places such as aluminum railings on bridges and for repairing aluminum handrails outside. It also serves as a perfect solution to temporary fix cracks on aluminum frames of large trailers as we perform these welding repairs on truck inspection station on the 401 highway. Stick aluminum welding serves us very well in tough Canadian winters when we must weld outside aluminum attachments to variety of specialized heavy equipment or machinery. So where is the catch, where is our comparative advantage?

Experienced in stick aluminum welding

Well, every welder who even once tried to weld aluminum with a stick aluminum welding rod can tell you one thing. It is not easy. Simply put, the welder does not see the welding puddle and the weld itself, speed is fast, extensive cleaning is necessary and the weld appearance leaves a lot to be wish for. The skill of the welder shines during stick aluminum welding. The hand must be used to the speed and an aluminum welding rod has to follow the imaginary path in the welder’s mind since the welder does not see much there.

Selection of proper stick aluminum welding rods

Proper selection of aluminum welding rods matters in stick aluminum welding. Every manufacturer in North America of stick aluminum welding rods says that its rods are good. Unfortunately, after testing rods from 9 manufacturers, we have found out huge differences between these rods. Some aluminum welding rods exhibit uncontrolled behavior, and some are very difficult to control in other positions except flat position. After testing we have selected only one manufacturer that makes very good aluminum welding rods. These aluminum welding rods make our stick aluminum welding much easier. At present time we offer stick aluminum welding with rods 3XX and 4XX series. We do not offer aluminum welding with 5XX series aluminum welding rods

Knowing the limitations of stick aluminum welding

Knowing the limitations of stick aluminum welding is crucial since these limitations forces us to change the welding technique. One limitation is thickness of material which is about 1/8” in overhead position. Second is the necessity of preheating especially in winter. Third is lack of controlled penetration and then lack of complete assurance as to the weld’s strength. Forth is messy look of the weld and then necessity for clean up and smoothing.

Tig or GTAW welding aluminum – cast aluminum welding

The major advantage of GTAW for cast aluminum welding is control that includes penetration and the associated weld’s strength. Other strengths are weld purity, its cleanness and a good appearance. That is why GTAW is so useful for welding cast aluminum. Control of sinking paddle leaves no guessing as to the weld strength and variety of aluminum wires allow for a better filler match to the existing aluminum cast. Another advantage focuses on control of comfortable welding speed which depends on the cast shape and its thickness. The disadvantage of GTAW for cast aluminum welding relates to overheating that will cause an irreversible damage. Especially in case of thin aluminum cast the temperature control techniques such as heat monitoring and heat dispersal are very important. We offer GTAW aluminum welding in a portable setup since a construction Tig set up is not suitable for aluminum. Windy conditions could make GTAW aluminum welding difficult or impassible in such cases we use umbrellas or our welding tent. Also stick welding could be used for temporary tacking of broken aluminum casts.

Mig welding aluminum – mobile and portable setups

We provide (GMAW) Mig welding aluminum in the mobile setup using push-pull gun and in a portable setup with a spool gun with 25 feet leads for large jobs. Majority of mig aluminum welding can be accomplished with our mobile welding set up as long as the job has and easy access. Mig aluminum welding offers almost the same penetration as GTAW but lacks sufficient control so useful for cast aluminum welding. Some in place testing will be necessary if proper measurement of aluminum elements being welded is not possible. The speed of mig aluminum welding is a major advantage of this technique. Although for certain setups GTAW speed could be comparable to Mig for aluminum welding. Windy conditions also negatively impact mig aluminum welding, but we find that they do not affect mig welding aluminum as badly as in case of GTAW. Sometimes it is only necessary to increase the shielding gas flow.

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