PROCEDURAL HANDBOOK. SuperGlaze 5356 TM

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Ambrose McKenzie
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1 PROCEDURAL HANDBOOK SuperGlaze 5356 TM

2 SUPERGLAZE 5356 TM Aluminum Welding for Trailer Manufacturing The use of wrought and cast aluminum base materials continues to increase. In trailer manufacturing, aluminum is used because it is light weight, strong, and extremely corrosion resistant. Only Lincoln Electric is able to provide total welding solutions for aluminum: Fully integrated manufacturer of premium aluminum welding consumables Aluminum welding consumables engineered with a specific alloy system designed for the trailer manufacturing industry Advanced multi-process power sources with advanced weld data collection tools. Customized aluminum waveform technology allows the operator to select the right waveform for the application. Welding Aluminum vs. Welding Steel Aluminum MIG welding can be more difficult than welding other materials because aluminum conducts electricity better. Small changes in wire diameter, wire feed speed, and current produce dramatic changes in weld bead profile, arc length and on occasion can cause equipment downtime due to wire burn back. Most aluminum MIG welding problems are caused by poor feeding. Since aluminum is relatively soft, it is important that the wire surface be as smooth as possible for best feedability. SuperGlaze products provide superior feeding compared to competitive products, resulting in fewer surface imperfections. Lincoln Electric is the only aluminum welding wire manufacturer to triple shave its aluminum wire for smoothness and cleanliness. SuperGlaze wire feeds with less force than typical competitive products which means better control of the weld puddle for the operator and extended gun liner and contact tip life. Manufacturing Quality Aluminum Welding Wire The manufacturing process of aluminum MIG wire is complex, and Lincoln Electric has a distinct advantage. Aluminum Rod Mill Lincoln Electric uses automated tilting furnaces to efficiently produce the proper aluminum alloys. With this equipment, we are able to hold tight tolerances in the composition. The alloy is carefully refined prior to casting to minimize hydrogen, alkaline metals, and inclusions. Continuous Casting Process Specially configured to aluminum alloys. This process keeps the surface free from imperfections and impurities. Drawing the Wire In the last step of the manufacturing process, we use advanced wire drawing technology to preserve both surface integrity and internal soundness. Testing the Wire To ensure superior quality of welding wire, continuous product testing is done. Surface quality is evaluated along with feedability and welding performance. This guarantees every spool and box of wire is problem-free.

SuperGlaze 5356 TM SuperGlaze 5356 TM is an engineered aluminum alloy GMAW wire designed specifically for applications in the trailer manufacturing industry.

Maximum Arc Performance and Stability Proprietary manufacturing processes provide the smoothest surface finish in the industry.

1 kg) Master Carton ED034064 ED034065 ED034066 16 lb (7.3 kg) Steel Spool ED034067 ED034068 ED034069 Diameter in. (mm) 0.035 3/64 1/16 (0.9) (1.2) (1.6) 20 lb (9.

constant voltage output (CV) for light industrial job fabrication, maintenance, or repair work.

3 SuperGlaze 5356 TM SuperGlaze 5356 TM is an engineered aluminum alloy GMAW wire designed specifically for applications in the trailer manufacturing industry. The engineered alloy system provides optimal arc stability and excellent wetting for both semi-automatic and high productivity automatic applications. Key Features: Superior Wetting Unparalleled bead profile and appearance which are critical for groove and fillet welds on aluminum trailer beds. Enhanced Arc Stability and Control Engineered chemical composition developed specifically to outperform standard ER5356 electrodes giving the operator unprecedented control. Maximum Arc Performance and Stability Proprietary manufacturing processes provide the smoothest surface finish in the industry. This makes it ideal for automatic applications on formed truck panels. DIAMETERS / PACKAGING Diameter in. (mm) /64 1/16 (0.9) (1.2) (1.6) 1 lb (0.4 kg) Plastic Spool 20 lb (9.1 kg) Master Carton ED ED ED lb (7.3 kg) Steel Spool ED ED ED Diameter in. (mm) /64 1/16 (0.9) (1.2) (1.6) 20 lb (9.1 kg) Plastic Spool ED ED lb (136 kg) Accu-Pak Box ED ED ED Recommended Equipment: POWER MIG 6 with spool gun Aluminum MIG welding power source capable of constant voltage output (CV) for light industrial job fabrication, maintenance, or repair work. POWER MIG MP Aluminum MIG welding power source utilizing Lincoln Electric Chopper Technology to deliver high quality welds by increasing the control over the welding arc and multi-process capable for welding aluminum with pulsed MIG and advanced processes like Pulse-On-Pulse and Power Mode. Power Wave C, S & S Advanced multi-process power sources with the most comprehensive weld data collection tools and customized aluminum waveform technology allows the operator to select the right waveform for the application.

4 SUPERGLAZE 5356 TM Lap & Fillet Weld SuperGlaze 5356 TM has a unique wire chemistry optimized for trailer manufacturing welding applications and will perform differently than standard ER5356 alloys. The following procedures are recommended for lap and fillet welds including high speed robotic fillet welds or semi-automatic lap welds on 6XXX series base materials. The following procedures should be used as a general guideline. FRONT SIDE SIDE SIDE Shorter contact to work distance (CWTD) is recommended for aluminum: 1/2 in. (12 mm) to 5/8 in. (16 mm). To minimize a cold weld bead at the beginning, use the start feature on the POWER MIG or Power Wave power source. To reduce the likelihood of crater cracking, use the crater fill feature on the POWER MIG or Power Wave power source /16-3/8 in. PROCESS: CONSTANT VOLTAGE (CV) Thickness in (mm) WFS Volts in (0.9 mm) Diameter Amps (approx.) /64 in (1.2 mm) Diameter /16 in (1.6 mm) Diameter

PROCEDURES PROCESS: PULSE Thickness in (mm) WFS Trim Volts Amps (approx.) 0.035 in (0.9 mm) Diameter 18 18 50 70 5 650 700 1.

5 PROCEDURES PROCESS: PULSE Thickness in (mm) WFS Trim Volts Amps (approx.) in (0.9 mm) Diameter PROCESS: POWER MODE Thickness in (mm) WFS Power kw/hr Volts Amps (approx.) 3/64 in (1.2 mm) Diameter 3/64 in (1.2 mm) Diameter /16 in (1.6 mm) Diameter 1/16 in (1.6 mm) Diameter

6 SUPERGLAZE 5356 TM Butt & Groove Weld SuperGlaze 5356 TM has a unique wire chemistry optimized for trailer manufacturing welding applications and will perform differently than standard ER5356 alloys. The following procedures are recommended for butt and groove welds including formed truck panels and multi-pass groove welds. The following procedures should be used as a general guideline. FRONT SIDE SIDE SIDE 1/16-3/8 in. PROCESS: CV Thickness in (mm) WFS Volts in (0.9 mm) Diameter Amps (approx.) /64 in (1.2 mm) Diameter Shorter contact to work distance (CWTD) is recommended for aluminum: 1/2 in. (12 mm) to 5/8 in. (16 mm). To minimize a cold weld bead at the beginning, use the start feature on the POWER MIG or Power Wave power source. 1/16 in (1.6 mm) Diameter To reduce the likelihood of crater cracking, use the crater fill feature on the POWER MIG or Power Wave power source

PROCEDURES PROCESS: PULSE Thickness WFS Trim Volts Amps (approx.) 0.035 in (0.9 mm) Diameter 0.85 5 650 700 1.05 21 80 95 110 140 160 PROCESS: POWER MODE Thickness WFS Power kw/hr Volts Amps (approx.

7 PROCEDURES PROCESS: PULSE Thickness WFS Trim Volts Amps (approx.) in (0.9 mm) Diameter PROCESS: POWER MODE Thickness WFS Power kw/hr Volts Amps (approx.) 3/64 in (1.2 mm) Diameter 3/64 in (1.2 mm) Diameter /16 in (1.6 mm) Diameter 1/16 in (1.6 mm) Diameter (1) Requires groove

8 SUPERGLAZE 5356 TM Troubleshooting Welding Defects Causes and Cures Some weld defects or discontinuities may be small enough that they don t seriously impair the mechanical properties of the weld joint. Other discontinuities may cause immediate joint failure. The effects of other discontinuities may be more insidious. It is not the purpose of this section to assess the acceptability or rejectability of specific discontinuities. Instead, the appearance of the various types of weld defects will be illustrated and methods to eliminate or minimize these defects. Cracking Cracking occurs when a combination of a susceptible microstructure or chemistry and a sufficiently high solidification stress are present. If you reduce the stress or change the microstructure or chemistry, the cracking can be eliminated. All weld cracking in aluminum is caused by hot cracking. That is, it takes place during weld solidification. CRATER CRACKING If the arc is extinguished rapidly, there isn t enough filler metal present to avoid forming a deep crater. The geometry of the crater locally intensifies the solidification stresses. If they are high enough, a crack forms in and around the crater. In order to eliminate crater cracking, the geometric discontinuity of the crater must be minimized, i.e., the crater must be filled in as much as possible. There are several methods to prevent crater cracking: Use a power supply with a crater fill option. Rapidly restrike and extinguish the arc a few times while keeping the wire tip in the crater. This will build up the crater. Run the weld bead to the end of the workpiece, then reverse direction and increase travel speed in the new travel direction. LONGITUDINAL CRACKING Longitudinal cracking occurs relatively frequently. Weld cracking can usually be eliminated by taking following precautions: Heat treatable alloys are crack sensitive and will crack if welded autogenously. Make sure you add filler metal. Make sure you add enough filler metal in welding any alloy. Do not deposit thin, concave groove welds or small or concave fillets. They may crack. Weld passes in both groove welds and fillet welds should be slightly convex. If cracking is encountered in making a square butt weld, try a V-Groove preparation. It will allow more surface area of the base material to be included in the joint. Similarly, if you re using a bevel prep, go to a V-prep. Reduce the clamping pressure to allow the material to move slightly during solidification. Restraining the part can cause stress on the weld as it cools, solidifies and contracts. Occasionally high stress is caused by the joint geometry, which may need to be changed. LIQUATION CRACKING Liquation cracking is common in lap and fillet welds in thin heat- treatable alloys. It usually is not seen in the non heat-treatable alloys or in butt joints. It manifests itself as a short longitudinal crack in the parent material on the back side of a weld. It is caused by the melting of low melting point compounds which tend to segregate to the grain boundaries in heat-treatable alloys. In order to minimize it, weld penetration into the parent metal needs to be controlled in lap and fillet welds. Welds having 30 or 40% penetration into the parent metal will almost never cause a crack, while welds penetrating 70-80% into the parent metal will often cause a small crack on the back side of a weld.

9 TROUBLESHOOTING Incomplete Penetration Incomplete penetration is often caused by insufficient weld current at a welding travel speed that is too high. However the use of an arc voltage that is too high can also result in the arc bridging the weld root and not penetrating completely. Care must also be taken in backgouging a two sided weld. Insufficient backgouging can sometimes result in incomplete penetration. It is sometimes surprising how deep the backgouge must be to get to sound metal. Porosity Porosity in aluminum welds is caused by bubbles of hydrogen gas which are trapped in the welds as it cools. The source of this hydrogen is oils, greases, or water vapor that is dissociated by the welding arc. In order to control weld porosity, the sources of these contaminates must be eliminated. It is also helpful when welding in the vertical position, to use an upward progression, rather than the downward progression usually used to weld steel, to minimize weld porosity. Porosity can usually be eliminated by taking the following precautions: Remove oils and greases from the surface of the base material. Wiping with a clean rag saturated with a degreasing solvent. This method is very effective. Mild alkaline solutions make good degreasers. The part to be degreased can be sprayed with these solutions or dipped into a tank containing them. Since such cleaners are usually water based, it is important to thoroughly dry the part after degreasing. Acid based cleaning solutions for cleaning aluminum. These are usually effective. However, all are acidic and some contain hydrofluoric acid, so caution in their use and disposal is required. Again, since they contain water, the piece must be thoroughly dried before welding. Remove excess oxides. Brush lightly with a stainless steel wire brush. Oxide removal can also be performed by immersing the part in a strong alkaline solution. Interpass cleaning. Remove oxides and weld smut (composed largely of aluminum oxide and magnesium oxide) before depositing another pass with a stainless steel wire brush using light pressure. Copper contamination will also appear white on a radiograph. Copper contamination is usually larger and fuzzier than tungsten, which appears as individual small particles. Copper contamination is often encountered in GMAW and is caused when the wire burns back and fuses to the copper contact tip. The copper and aluminum quickly alloy and deposit copper in the aluminum weld. If this occurs, the copper contamination must be ground out and repaired because the aluminum/copper alloy that is deposited is very brittle. Copper contamination can also be caused by copper backing bars or copper tooling. While the use of copper backing bars is acceptable, the joint preparation must be such that the arc is not allowed to impinge directly on the copper bar. If it does, the copper bar will melt and alloy with the aluminum. While copper backing bars are acceptable, wide root openings must be avoided.

10 SUPERGLAZE 5356 TM Troubleshooting Chart PROBLEM V SOLUTION?o ? + + Increase - Decrease Inspect & Replace Important This guide is for trouble shooting purposes. One of the solutions should be tried at a time and the variable should be adjusted slightly to see if the variable is the root cause of the problem.

Procedure Notes All listed procedures are starting points and may require some adjustment depending on the specific application.

Operators typically reduce the arc length control (Trim) to achieve this.

At higher travel speeds, joint fit up, wire placement and contamination all become factors that are more significant.

Depending on the limitations/requirements of the actual application, slower travel speeds and higher arc voltages may be required.

There is a point at which the arc is set so short that the arc will become unstable and stubbing will occur. This forms a limitation of just how fast the travel speed can be raised.

Welding Safety Arc welding is a safe occupation when proper safety measures are taken to protect the welder from potential hazards.

Your Trusted Partner for Welding Safety Solutions The Arc Welding Safety Brochure provides both mandatory safety practices and those based on shop experience.

11 Procedure Notes All listed procedures are starting points and may require some adjustment depending on the specific application. As the travel speed increases in fast follow applications, a tighter and arc length must be maintained so that the puddle properly follows the arc. Operators typically reduce the arc length control (Trim) to achieve this. Torch angle, electrode placement, contamination, mill scale, joint fit up and joint consistency are factors that may require special consideration depending on the specific application. At higher travel speeds, joint fit up, wire placement and contamination all become factors that are more significant. The results of welding at higher travel speeds is a tendency to produce more spatter, less penetration, more undercut and a less desirable bead shape. Depending on the limitations/requirements of the actual application, slower travel speeds and higher arc voltages may be required. At faster travel speeds, the bead-shape can become very convex (or ropey) and the weld will not wet well. There is a point at which the arc is set so short that the arc will become unstable and stubbing will occur. This forms a limitation of just how fast the travel speed can be raised. It is ultimately the responsibility of the end user to ensure the proper weld deposition rate, bead profile and structural integrity of a given weld application. Welding Safety Arc welding is a safe occupation when proper safety measures are taken to protect the welder from potential hazards. When these measures are overlooked, welders can encounter dangers such as, electric shock, overexposure to fumes and gases, arc radiation, fire and explosion. Your Trusted Partner for Welding Safety Solutions The Arc Welding Safety Brochure provides both mandatory safety practices and those based on shop experience. The Lincoln Electric Company Automation Division 1 Saint Clair Avenue U.S.A. Cleveland, OH Phone: d-solutions MC11-45 (09/11) Printed in the U.S.A. Lincoln Global, Inc. All Rights Reserved. Check out the Interactive Welding Safety Program Designed to educate arc welders about the safety hazards they may encounter while arc welding and the safe practices they should follow to minimize those hazards. Welding Safety INTERACTIVE DVD M C / T he L inco ln Ele ctric Com pany All Rights Res er ved. For more information about welding safety or to download materials go to CU S T O M E R AS S IS TAN C E PO LIC Y The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for information or advice about their use of our products. Our employees respond to inquiries to the best of their ability based on information provided to them by the customers and the knowledge they may have concerning the application. Our employees, however, are not in a position to verify the information provided or to evaluate the engineering requirements for the particular weldment. Accordingly, Lincoln Electric does not warrant or guarantee or assume any liability with respect to such information or advice. Moreover, the provision of such information or advice does not create, expand, or alter any warranty on our products. Any express or implied warranty that might arise from the information or advice, including any implied warranty of merchantability or any warranty of fitness for any customers particular purpose is specifically disclaimed. Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements. Subject to Change This information is accurate to the best of our knowledge at the time of printing. Please refer to for any updated information.

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