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How to Weld Tempered Aluminum

Tempered aluminum is an aluminum alloy that has been aged to control its mechanical properties (ie, improving ductility and reducing cracking), either by cool working, in which the aluminum is strengthened via mechanical stresses, or by heat treatments, in which aluminum undergoes cycles of heating and cooling. Welding reduces the tensile strength of both kinds of tempered aluminum. Therefore, consider either using an alternative to welding, such as bolted or riveted joints, or strengthen your design with gussets and bracing after welding.

Gussets
Bracing
Welding machine
Electrode

Instructions

- 1
  Insert the electrode that you want to weld to your aluminum into your welding rod.
- 2
  Connect the welding machine to AC power. Connect the earth wire from the welding machine to the base metal. Touch the electrode to the surface of the tempered aluminum, thus completing the circuit. The electrode will "spark up," generating great amounts of heat that melt not only the electrode, but also the surface of the base metal, so the two fuse.
- 3
  Connect the welding machine rods to gussets (used for reinforcement at three or more parts on the base metal) or brackets, sufficient to cover the area that you welded. Touch the reinforcing materials to the base metal at the site of welding, allowing both them and the base metal to heat up and fuse together.

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