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Welding aluminum is not an easy task

The high electrical and thermal conductivity of aluminum, very low weight, combined with the excellent mechanical properties of its alloys, have made this material simply irreplaceable in many areas of production. But with all our unique properties This metal is very difficult to weld. The ability to weld aluminum with high quality is what distinguishes a highly qualified welder from an amateur welder.

There are two main methods of welding aluminum parts:

• MIG welding of aluminum semi-automatically
• Argon arc TIG welding of aluminum
  

Sometimes there is a need to connect aluminum parts to each other, but there is no suitable welding machine or professional welder at hand, and the strength of the connection does not play a special role. In this case, the method described in our video instructions will come to the rescue.

You will need:

• Propane torch
• Aluminum soldering rods
• Surface degreasing liquid
• Clamps for holding parts together

"Welding" aluminum without using a welding machine

Attention

In fact, this is certainly not welding. This method can perhaps be called soldering. Despite this, this method is quite suitable in the case when the parts being connected will not experience strong loads, and not strong ones either. For example, for the manufacture of decorative items and souvenirs.

So, if you need to weld aluminum parts, use the services of professionals. Or buy welding machine and become a professional yourself. Good luck!

The popularity and demand for aluminum pipes are determined by a number of factors: distinctive characteristics. These are also competitive advantages, which include:

• strength,
• light weight,
• high corrosion resistance,
• convenience
• ease of installation.

Let's talk about the latter

The main method of connecting aluminum pipes is welding. Many welders do not like this metal, since working with aluminum, due to its physical and chemical nature, has its own specific difficulties. The slightest mistake can lead not only to partial damage to the product, but also to its subsequent complete unsuitability.

There are often cases when the electrode or cutting torch is overexposed, resulting in a hole. It is very difficult to correct this shortcoming. To prevent these and similar problems, it is important to follow some recommendations.

What type of welding is suitable for installing aluminum pipes

Gas welding is considered the most convenient and expedient way to connect and install aluminum pipes. For these purposes, gases such as acetylene, argon or a propane-butane-oxygen mixture can be used equally effectively. Naturally, this welding method requires the use of specialized equipment, which is very expensive. These are gearboxes, hoses, cylinders, replaceable mouthpieces, etc. If you rarely work with aluminum pipes, we recommend using electric arc welding.

Purchased or self-made electrodes

For electric arc welding of aluminum, special electrodes are used (one of them is UANA). They are not cheap, and sometimes they are quite difficult to find. If electrodes are needed urgently, you can resort to the following manufacturing method. We take aluminum wire (diameter 3-4 millimeters), ordinary chalk and silicate glue (sometimes called liquid glass).
We cut the wire 25-30 centimeters long, finely grind the chalk and mix it with glue, obtaining a homogeneous coating, which we then apply to the wire with a layer of 1-2 millimeters and dry well. The electrode is ready for use.
Before installing aluminum pipes, the joined products are thoroughly cleaned of oxidized film and other contaminants. You can use sandpaper or wire brush. When cleaning is completed, it is necessary to warm up the pipes. You can use traditional gasoline burner. It is important not to overheat the products.

Features of installation of aluminum pipes

Welding aluminum pipes has its own characteristics:

• Electrodes burn out quickly, stock up on plenty;
• The weld seam freezes at lightning speed;
• At the end of the seam, the electrode should be pulled off smoothly, without sudden movements, so that a leaky and unsightly crater does not form;
• The speed of movement of the electrode is 3-4 centimeters per second.

Aluminum pipe due to its qualities is quite common building material. It can be used in the construction of various pipelines, drainage and ventilation systems, as well as for the manufacture various designs. How to choose the right pipes, join and lay pipes, read on.

Areas of use of aluminum pipes

Pipes made of aluminum have the following positive qualities:

• resistance to corrosion. This factor significantly increases the scope of use of pipes and their service life;
• light weight, which is reflected in the ease of delivery of pipes and their installation;
• resistance to chemicals And aggressive environments. Thanks to this factor, pipes can be used for laying underground pipelines;
• high cross-country ability. Thanks to the smooth inner surface pipes made of aluminum can pass more liquid than pipes made of other materials of the same diameter;
• processing capability. Pipes can be painted, sewn up with any materials, mounted in a wall, and so on. Any way will not work negative influence and will not reduce their service life.

All presented qualities apply to pipes consisting of 95% aluminum or more.

The positive characteristics of aluminum products determine the scope of their application. Pipes made of this metal can be used:

• for construction, drainage, heating, ventilation, both domestic and industrial purposes;
• for the construction of drainage systems;
• for the construction of a storm sewer network;
• for laying pipelines for the oil production and oil processing industries;
• for electrical cable insulation;
• for the construction of building frames;
• for the construction of gazebos, benches, greenhouses and other small architectural forms.

Main selection criteria

When choosing aluminum pipes for the construction of a particular facility, the following aspects should be taken into account:

• pipe manufacturing method;
• diameter, shape and other dimensions.

Pipe making methods

IN modern production The following methods for manufacturing aluminum pipes are used:

• cold deformation. A pipe with specified parameters is made from aluminum circle by pulling and subsequent calibration. This method allows the production of pipes with exact dimensions, including those with a minimum diameter and high quality. The main disadvantage is the high cost;

• pressing. Heated aluminum billets are passed through a special press with specified parameters. Pressed pipes are characterized by increased resistance to mechanical stress;

• welding An aluminum billet with specified dimensions is bent into the shape of a pipe. The ends of the workpiece are welded together. Pipes made by welding are most susceptible to cracking when high blood pressure or mechanical stress. Therefore, it is recommended to use them exclusively for domestic purposes and within reach for inspection and repair work.

Selection of basic parameters

Aluminum pipes can be round, square, rectangular:

• round and oval pipes are mainly used in the construction of pipelines and ventilation systems;
• square and rectangular (profile) pipes are used for laying cables, constructing building frames, and constructing various structures.

Before constructing any structure, you should also take into account such parameters as:

• diameter of the pipe used. This parameter is of particular importance during the construction of water supply, etc., since the throughput of the system depends on the diameter;
• aluminum pipe wall thickness. The size depends on this parameter maximum load, which is of fundamental importance when laying pipelines underground or constructing various structures.

Each type of pipe is manufactured in accordance with GOST, which also regulates standard sizes manufactured products. So:

• cold-deformed aluminum pipes must comply with GOST 18475 - 82;
• pressed pipes are manufactured according to GOST 18482 - 79;
• The welded pipe complies with GOST 23697 – 79.

GOST also regulates pipe inspection and testing methods, which guarantees high quality manufactured products.

Methods for connecting aluminum pipes

Before constructing any pipelines or other types of structures, you should familiarize yourself with possible ways connections of aluminum pipes.

The main method of connection during pipeline construction is welding, which is performed according to the following scheme:

1. pipes are prepared for welding work: cutting, stripping, and so on;
2. preparation of the device. Welding of aluminum pipes can be done using a gas torch (argon welding) or conventional welding equipment (electric arc welding). In the latter case, it is necessary to purchase special electrodes;
3. joining pipes and applying a weld.

The welding process is presented in more detail in the video.

The profile pipe used in the construction of frames and other forms, in addition to welding, can be connected using bolts. To do this you need:

1. cut pipes in accordance with the dimensions specified by the future design diagram;
2. sand the edges of the pipes with sandpaper;
3. drill holes for installing bolts;
4. assemble the structure using connecting plates.

When installing various structures, you can use other methods, for example, arranging a connection with a threaded fitting, but all similar methods are labor intensive and can lead to a violation of the system’s sealing.

If you are wondering how to connect two aluminum pipes, we will talk about the intricacies of this matter and reveal its small tricks. The need for this operation appears quite often in everyday life and sometimes very experienced craftsmen can be confusing. Typically, this task is performed using welding or threading. But there are other ways. After all welding work not only expensive, they require professional equipment and a specialist and cannot always be performed in the right place. In addition, sometimes pipes need to be connected very quickly, without waiting for the welder to arrive with the equipment.

Fittings can do anything

To quickly and reliably connect aluminum pipes at home, special fastening elements - fittings - have been created.

They are divided into two types:

• along the cross-section of the elements to be connected: straight (two identical diameters) and transitional (two different diameters),
• by purpose: corners and bends, tees, couplings, crosses, fittings, adapters, plugs, caps.

Fittings not only productively solve the problem of how to connect aluminum pipes without welding, but also simplify the process of installing any communication networks or manufacturing various structures.

The most popular fittings are the crimp type of installation, or more precisely, press fittings.

Why are compression fittings recommended:

• the joining of pipes is completely sealed,
• strength and reliability of the connection,
• vibration resistance.

Types of fittings

Couplings are the most commonly used type of fitting elements. High-quality couplings with fasteners allow you to quickly and reliably ensure reliable joining of two or more pipes. A variation of it called the Gebo coupling is also often used.

Flanges with rubber gaskets ensure reliable joining of pipes. It is preferable to select such elements with a large cross-section.

Also, the question of how to connect an aluminum pipe to each other can be answered by a device such as a repair and installation clip. This is a coupling or triple type of fitting, consisting of 2 parts attached to each other. This is very good way for an express option for joining pipes - for example, in case of an accident or other emergency situation.

No less effective and simple is the method of joining pipes using a clamp, which ensures a reliable connection. It tightens on one side, which makes it different from a clip. The connection is therefore considered more durable.

How to Join Square Aluminum Tubes

Aluminum pipes of square, rectangular or other cross-sections are usually connected using a crab system or clamps.

The crab system is narrow strips of metal made of 2 parts connected to each other. They have the shape of the letters T, X or G and can securely cover pipe sections. The resulting joints are highly reliable. But the joining occurs only at right angles and is made for pipes with a small cross-sectional size.

A more universal method of joining pipes complex profile is the clamp. We offer to select and buy aluminum pipes on our website at competitive prices and in a wide selection.

Soldering aluminum at home, technologies, methods

1. The simplest and in a reliable way, connect or attach something to aluminum or its alloys - this is, of course, a bolt and nut or rivets. All other methods require some preparation, fixtures, special solders, fluxes for soldering aluminum, etc.

As practice shows, aluminum cannot be soldered at all in the usual way, tin-lead solder, the reason for this is the oxide film, which forms almost instantly after cleaning the surface to be soldered.

2. Therefore, one of the ways to solder aluminum is to cover the surface, immediately after cleaning, with a layer of molten rosin. Not the best, but after repeated attempts, rubbing the soldering iron tip over the soldering area can achieve satisfactory results.

3. Next, you can use a solution of rosin in diethyl ether to solder aluminum. We clean the surface and immediately lubricate it with this flux, and then sprinkle it with copper filings, which serve as an abrasive to remove the oxide film, and tin the soldering area with ordinary solder (tin-lead). Afterwards, solder to the tinned area copper wire or something else.

4. The next technology for soldering aluminum is the use special solder for soldering aluminum and flux. Most of these solders are low-temperature, but their melting point is higher than that of tin-lead, in the range of 300-600 degrees. C. The key to success is also good warming up and for this they use gas burner or a blowtorch.

High-temperature solders are used for soldering massive parts; they are used to repair and restore parts made of aluminum and its alloys of any complexity (cars, motorcycles, etc.). The soldering turns out to be very strong. In this way, tubes, for example aluminum and copper, are soldered by inserting one into the other and soldering around. But, when soldering aluminum with other metals, make sure that the solder and flux are intended for one and the other metal.

The surface is cleaned and coated with a special flux, as in previous cases, and when the solder melts, you can scrape the solder area with the tip of a knife made of of stainless steel(or a stainless steel brush) to better remove the oxide film. Thus, we tin the aluminum surface and solder everything we need to it.

This is not the end of the methods for soldering aluminum at home. You can use the electrochemical method.

5. Clean the surface and apply a few drops of CONCENTRATED solution to the soldering area copper sulfate. Then, we take a power supply of 5-12V and a current of about 1 ampere (more is possible), connect a resistance of 4-5 Ohms and a powerful one to the power supply. 5-10 W, and our device is ready. We calculate the load in such a way that the power supply does not burn out during operation, i.e., at a current of approximately 1-5 Amperes.

Now we connect the aluminum blank to the negative pole of the power supply, and to the positive pole we connect a bare copper wire (you can twist it into a small flat spiral), which is then introduced into a drop of vitriol solution so that the end does not touch the surface of the part. Everything is ready, turn on the power supply and wait a few minutes. A layer of copper, as a result of electrolysis, will settle in place for soldering. And then, wash it off (but don’t try to erase the copper), tin it, and solder the wires or terminal. This method, of course, is not suitable for soldering some massive parts, but it is suitable for contacting wires.

6. Alternatively, instead of vitriol solution, you can use hydrochloric acid: drop a drop into the soldering area and then move the copper drive along the contact pad. Copper precipitation occurs faster than in the first case, but you must be careful with the acid. And be sure to thoroughly rinse the soldering area with water.

Connecting copper pipes: instructions and comparison of various installation technologies

To prevent the acid from corroding the excess area, it can be sealed with tape or filled with paraffin, and the desired area can be exposed. That. You can solder aluminum with copper and other metals, and the contact pads will have a beautiful, neat shape.

That's all, but if there are any other ways to solder aluminum or additions to the above, write.

Victor Donskoy
www.masteru.org.ua