Common Welding Defects and Solutions for Aluminum Alloy Welding

To weld aluminum and aluminum alloys, it is necessary to select a suitable welding wire and consider comprehensively according to the requirements of the type of base metal, the crack resistance of the butt joint, the mechanical properties, and the corrosion resistance. In general, better corrosion resistance can be obtained by selecting welding wire with the same or similar grade as the base metal composition. However, if the aluminum alloy to be welded has a high tendency to hot cracking, the selection of welding wire should focus on its crack resistance.

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Common defects (welding problems) and preventive measures:

Hot crack

Hot crack is a common defect in aluminum alloy welding, the main reason is fracture caused by thermal stress. To solve this problem, the practice has proved that thermal stress can be effectively reduced by adopting the appropriate welding form, controlling the welding process parameters, and performing the preheating and post-heat treatment.

Porosity and slag inclusions

Porosity and slag inclusions are common defects in aluminum alloy welding. To solve these problems, parameters such as atmosphere, gas flow, pipeline purification, and dosage during welding need to be strictly controlled. Especially for the problem of pores, it can be dealt with by chemical cleaning and mechanical cleaning.


Inclusions are another common problem during the welding of aluminum alloys. Inclusions can affect the strength, toughness, and corrosion resistance of welds. To reduce the influence of inclusions on welding performance, it is necessary to increase the number of additives and increase the welding speed to solve the problem.


Cracks are a difficult problem in the welding process of aluminum alloys. Cracks mainly occur in the heat-affected zone, and the cause is usually thermal stress caused by factors such as overheating and overcooling. To reduce the generation of cracks, it needs to be solved by proper preheating and post-weld annealing.

Common defects in aluminum alloy welding mainly include thermal cracks, pores, slag inclusions, inclusions, and cracks. Defects can be effectively reduced through a reasonable selection of welding wire, control of welding parameters, preheating and post-heat treatment. In the aluminum alloy welding process, it is necessary to take comprehensive consideration according to the specific situation and take appropriate measures to ensure the welding quality and performance.

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Machine advantages:

Precision sheet metal cabinet: stable operation and high stability

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Precision cooling water tank: to ensure the constant temperature effect of the whole machine

During the welding process, temperature control is very critical. DXTECHINDIA handheld “four-in-one” fiber laser welding machine adopts a precision cooling water tank to ensure the constant temperature effect of the whole machine. The constant temperature water tank can quickly dissipate the heat generated during the welding process while ensuring the operating efficiency and life of the machine.

Fast welding speed: full solder effect is good

DXTECHINDIA handheld “four-in-one” fiber laser welding machine adopts a high-efficiency laser light source, which is fast and efficient. Its high-precision laser beam enables high-quality welding results. At the same time, the beam focus of the welding machine can be adjusted to achieve the best welding effect for different welding materials.

Hand-held welding head: flexible direction, welding at any angle

The machine adopts a hand-held welding head, which is flexible and easy to use and can be taken at hand, which can meet different needs. The welding head can be rotated 180 degrees, and the direction can be adjusted flexibly, which is convenient for welding at any angle and further improves welding accuracy.

Long service life: stable power output, can work for a long time

DXTECHINDIA handheld “four-in-one” fiber laser welding machine uses a laser source with long service life, stable power output, and can work for a long time. The long service life of the machine can not only save the cost of the replacement but also improve the efficiency of the equipment.

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