Aluminium alloys welding processes: Challenges, joint types and process selection

TLDR

Aluminium alloys are increasingly used in structural engineering because of their light weight, ease of machining, and corrosion resistance. The article examines surface‑related challenges in aluminium welding, focusing on limitations of weld processes and joint configurations. A critical review of the literature was conducted, drawing on data from eight industrial welding processes and six joint types. The study demonstrates that heat‑input control, hot cracking, porosity, and weldable thickness vary by process, that no single process is optimal for all alloys and thicknesses, and that a selection table and awareness of weld limitations help choose the appropriate process.

Abstract

Aluminium and its alloys have gained increasing importance in structural engineering due to advantageous properties such as light weight, ease of machining and corrosion resistance. This article presents surface-related challenges facing aluminium welding, specifically weld process limitations and joint limitations. The methodological approach is a critical review of published literature and results based on eight industrial welding processes for aluminium and six joint types. It is shown that challenges such as heat input control, hot cracking, porosity and weldable thickness vary with the process used and that there is no optimal general weld process for all aluminium alloys and thicknesses. A selection table is presented to assist in selection of the optimal process for specific applications. This study illustrates that knowledge of weld limitations is valuable in selection of appropriate weld processes.