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How to Weld Aluminum with Inverter-Based Power Supplies?

Aluminum is a popular metal for various applications, such as aerospace, automotive, construction, and marine. It has many advantages, such as a high strength-to-weight ratio, corrosion resistance, and recyclability. However, welding aluminum can be challenging due to its high thermal conductivity, low melting point, and tendency to form oxide layers. These factors can affect the weld quality and cause problems such as poor penetration, distortion, spatter, porosity, and cracking.

I. Two Main Types of Power Sources for Aluminum Welding

To achieve high-quality aluminum welds, you need to use the right equipment, techniques, and consumables. One of the most important factors in aluminum welding is the power source. The power source determines the arc characteristics and the weld performance. There are two main types of power sources for welding: transformer-based and inverter-based.

  • Transformer-based power sources are traditional welding machines that use a transformer to convert AC input power into DC output power. They are bulky, heavy, and inefficient. They also have limited control over the welding parameters, such as current, voltage, frequency, and balance. These limitations can result in unstable arcs and poor weld quality.

  • Inverter-based power sources are modern welding machines that use high-frequency switching technology to convert AC input power into DC output power. They then use pulse-width modulation (PWM) to adjust the output waveform according to the desired welding parameters. This allows for precise control over the arc characteristics and weld quality.

    Inverter-based power sources are also more compact, lightweight, and energy-efficient than transformer-based power sources. They can operate on different input voltages and frequencies, making them suitable for various applications and environments. They also have multiple welding modes, such as TIG (tungsten inert gas), MIG (metal inert gas), MMA (manual metal arc), and plasma cutting.

II. Inverter-based Power Sources for Aluminum Welding

One of the best examples of inverter-based power sources is the Ehave 2 CM Series from Megmeet. The Ehave 2 CM Series is a multi-process welder that can perform TIG, MIG, and MMA on various metals, including aluminum. It has a digital control panel that allows you to adjust the welding parameters easily and accurately. It also has a synergic function that automatically matches the wire feed speed to the welding current.

The Ehave 2 CM Series has a unique feature called an inverter pulse that enhances the performance of aluminum welding. Inverter pulse is a special mode that uses high-frequency pulses to modulate the welding current. This creates a narrow and concentrated arc that penetrates deeply into the base metal. It also reduces the heat input and minimizes the distortion and spatter.

III. How to Weld Aluminum with the Ehave 2 CM Series

To weld aluminum with the Ehave 2 CM Series, you need to follow some basic steps:

1. Clean the aluminum surface with a stainless steel brush or a solvent to remove any dirt, oil, or oxide layer.

2. Set up the power source according to the welding mode, material thickness, and joint type. 

3. Connect the ground clamp to the workpiece and the torch to the power source.

4. Turn on the gas supply and set the gas flow rate to 10-15 L/min. Use pure argon as the shielding gas for both TIG and MIG welding.

5. Hold the torch at a 10-15 degree angle from the workpiece and initiate the arc by pressing the trigger or touching the tungsten electrode to the metal.

6. Move the torch along the joint at a steady speed and maintain a consistent arc length and travel angle.

7. Add filler metal as needed by dipping the rod into the weld pool or feeding the wire through the torch.

8. Terminate the arc by releasing the trigger or lifting the tungsten electrode from the metal.

9. Allow the weld to cool down naturally and inspect it for any defects.

By following these steps, you can achieve high-quality aluminum welds with inverter-based power supplies like the Ehave 2 CM Series from Megmeet. If you want to learn more about inverter-based power supplies and their benefits for aluminum welding, you can visit Megmeet’s website or read these articles:

1. What is an Inverter Welder and How it Works

2. Weld Inverter: Aluminum welds with inverter-based power supplies

I hope this article helps you with your aluminum welding project.