Materials
Common problems when welding aluminium
Quick answer
Common aluminium welding problems: porosity from the oxide layer, feed jams from soft wire, and blow-through because the pool gives no warning. Fix with brushing, spool guns and fast travel.
Problem → cause → fix
| Symptom | Cause | Fix |
|---|---|---|
| Black sooty welds | oxide, dirty metal | stainless brush + acetone |
| Wire jams | soft wire in liner | spool gun, U rolls |
| Sudden drop-through | late pool recognition | hotter, faster, push angle |
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