Aluminum tubing is often instrumental in refrigeration systems, due to its high thermal conductivity. By the same token, however, this thermal conductivity often results in weld puddles forming at a particularly high rate, making aluminum particularly difficult to weld. You also must use special preparation and technique when welding aluminum tubing to avoid excessive formation of aluminum oxides. If unfamiliar with aluminum welding processes, consult an experienced welder before beginning to obtain best results and avoid personal harm.
- Grinder
- Degreaser
- Stainless steel brush
- GTAW (gas tungsten arc welder) machine
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Instructions
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1
Use a grinder to bevel the edges of the aluminum tubing, so that the groove between the two tubes is shaped like a trapezoid. Beveling helps to reduce the formation of aluminum oxides during welding, in regions between the tubes from which the welding tool will not be able to strip the oxides.
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2
Clean the aluminum tubing, using a degreaser to remove surface oils and a stainless steel brush to remove other debris.
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3
Fit the two pieces of tubing together, and tack-weld them together by using the welding tool to make small weld beads around the diameter of the tubing.
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4
Use the welding tool to lay down a weld bead around the entire length of the groove.