What makes working with aluminium different from other metals? Despite its lightweight and corrosion-resistant properties, aluminium presents several challenges during fabrication. Issues such as welding difficulties, material distortion, and surface contamination can affect the final product. Most aluminium fabrication companies in UAE invest in specialised techniques and equipment to manage these challenges effectively and ensure high-quality results.
Welding difficulties:
- Aluminium has a lower melting point compared to other metals, making it more prone to burn-through during welding. Additionally, its oxide layer requires proper cleaning before welding.
- Solution: Using Tungsten Inert Gas (TIG) or Metal Inert Gas (MIG) welding with the correct filler material can improve weld quality. Cleaning the surface thoroughly and preheating the metal can also help reduce defects.
Material distortion:
- Heat exposure can cause aluminium to warp or bend, affecting the accuracy of the fabricated parts. This is especially common in thin aluminium sheets.
- Solution: Controlling heat input during cutting and welding is key. Using clamps, fixtures, and a gradual cooling process can help maintain the metal’s shape.
Surface contamination:
- Aluminium surfaces are highly reactive and can attract dirt, grease, and oxidation, which may interfere with welding and finishing processes.
- Solution: Regular cleaning with non-corrosive solvents and proper storage methods can prevent contamination. Using stainless steel brushes specifically for aluminium can also keep the surface clean.
Difficulty in machining:
- Aluminium tends to stick to cutting tools, causing rough finishes and tool wear. This can lead to inconsistencies in the final product.
- Solution: Using sharp carbide tools and lubricants can improve the machining process. Maintaining the right cutting speed and feed rate can also help achieve smoother results.
Anodising challenges:
- Anodising improves the durability and appearance of aluminium, but inconsistencies in the process can lead to uneven coatings and color variations.
- Solution: Ensuring a clean surface and using controlled electrical currents can help achieve uniform anodised layers. Selecting the right grade of aluminium also affects the final finish.
Aluminium fabrication involves various challenges, but the right techniques and tools can ensure smooth production. By addressing welding issues, reducing material distortion, preventing contamination, improving machining, and refining anodising processes, fabricators can achieve high-quality results.