Aluminum Welders

Properly welding aluminum and advanced steels requires new methods and equipment. Their use in vehicle bodies is only going to increase over the next few years, so it is important that collision repair professionals start equipping themselves now with the knowledge and equipment necessary to properly return these vehicles to manufacturer specs.

Features offered by welders that are specifically designed for aluminum and advanced steel applications, like Chief Elektron Fusion Technologies new MIG/MAG welders, give technicians who are equipped with these modern tools more confidence about repairing the newest vehicles.

Chief’s MIG/MAG Aluminum welders transform a novice or even an average welder into a good aluminum welder. Shops should invest in a welder that gives their technicians the confidence that they’re doing right. Below is that confidence, find out more…


MULTIMIG 621

The 621 delivers high current output with Three Phase supply voltage

MultiMig-621Double Pulse feature – mechanically and electrically controls the welding parameters to make aluminum welding easier and for increased confidence.

  • Synergic pulsed technolgy is required by most OEMs for aluminum welding. Includes a complete set of synergic programs in memory for brazing, welding and aluminum wire.
  • Inverter technology enables precision electronic control of output power for better quality welds.
  • GREEN technology – Integrated Power Factor Correction (PFC) technology reduces input power by avoiding energy waste found in most electronic-based equipment and ultimately reduces operating costs. High Harmonic Distortion is hard on the power grid and contains non-working energy, which is costly & environmentally wasteful.
  • Two types of torches can be used with MultiMig power source – a standard MIG torch or the unique push-pull torch. The Chief Elektron Fusion Technologies push-pull system torch has an up-down digital current adjust at your finger tip, thanks to a feeder built into the grip. The very small and light weight torch (no bulky spool-gun) enables real-time control of welding process by control of the wire feed speed and current level. The push-pull system corrects many of the problems encountered when feeding and welding soft aluminum wire, down to 0.6mm.
  • Many programmable options are available to customize the unit operation to meet most working conditions. Options include: Arc Length, 2 time, 4 time, Spot Time, Pause Time, Inductance, Burn Back, Soft Start etc. Can operate in pulse synergic, synergic, or conventional mode.

MULTIMIG 522

Welding and brazing of aluminum alloys, galvanized sheet metal, stainless, and high-strength steel.

MultiMig522Double Pulse feature – mechanically and electrically controls the welding parameters to achieve a TIG-looking weld bead. Synergic pulsed welder with full set of welding programs for easy use.

  • Synergic pulsed technolgy is required by most OEMs for aluminum welding. Includes a complete set of synergic programs in memory for brazing, welding and aluminum wire.
  • Inverter technology enables precision electronic control of output power for better quality welds.
  • GREEN technology – Integrated Power Factor Correction (PFC) technology reduces input power by avoiding energy waste found in most electronic-based equipment and ultimately reduces operating costs. High Harmonic Distortion is hard on the power grid and contains non-working energy, which is costly & environmentally wasteful.
  • Two types of torches can be used with MultiMig power source – a standard MIG torch or the unique push-pull torch. The Chief Elektron Fusion Technologies push-pull system torch has an up-down digital current adjust at your finger tip, thanks to a feeder built into the grip. The very small and light weight torch (no bulky spool-gun) enables real-time control of welding process by control of the wire feed speed and current level. The push-pull system corrects many of the problems encountered when feeding and welding soft aluminum wire, down to 0.6mm.
  • Many programmable options are available to customize the unit operation to meet most working conditions. Options include: Arc Length, 2 time, 4 time, Spot Time, Pause Time, Inductance, Burn Back, Soft Start etc. Can operate in pulse synergic, synergic, or conventional mode.

MultiMig 511

Welding and brazing of aluminum alloys, galvanized sheet metal, stainless, and high-strength steel.

  • MultiMig511A push-pull torch designed specifically to optimize aluminum welding.
  • Built-in cart for easy welder handling, Includes storage for gas cylinder
  • Synergic pulsed welder with full set of welding programs for easy use.

Synergic pulsed technology is required by most OEMs for aluminum welding. Includes a complete set of synergic programs in memeory for brazing, welding and aluminum wire.
Inverter technology enables precision electronic control of output power for better quality welds.
GREEN technology – Integrated Power Factor Correction (PFC) technology reduces input power by avoiding energy waste found in most electronic-based equipment and ultimately reduces operating costs. High Harmonic Distortion is hard on the power grid wasteful.
Two types of torches can be used with MultiMig power source – a standard MIG torch or the unique push-pull torch. The Chief Elektron Fusion Technologies push-pull system torch has an up-down digital current adjust at your finger tip, thanks to a feeder built into the grip. The very small and light weight torch (no bulky spool-gun) enables real-time control of welding process by control of the wire feed speed and current level. The push-pull system corrects many of the problems encountered when feeding and welding soft aluminum wire, down to 0.6mm. Many programmable options are available to customize the unit’s operation to meet most working conditions. Options include: Arc Length, 2 time, 4 time, Spot Time, Pause Time, Inductance, Burn Back, Soft Start etc. Can operate in pulse synergic, synergic, or conventional mode.


MULTIMIG 521MultiMig521_Fusion

Welding and brazing of aluminum alloys, galvanized sheet metal, stainless, and high-strength steel.

Double Pulse feature – mechanically and electrically controls the welding parameters to achieve a TIG-looking weld bead. Synergic pulsed welder with full set of welding programs for easy use.

  • Synergic pulsed technolgy is required by most OEMs for aluminum welding. Includes a complete set of synergic programs in memory for brazing, welding and aluminum wire.
  • Inverter technology enables precision electronic control of output power for better quality welds.
  • GREEN technology – Integrated Power Factor Correction (PFC) technology reduces input power by avoiding energy waste found in most electronic-based equipment and ultimately reduces operating costs. High Harmonic Distortion is hard on the power grid and contains non-working energy, which is costly & environmentally wasteful.
  • Two types of torches can be used with MultiMig power source – a standard MIG torch or the unique push-pull torch. The Chief Elektron Fusion Technologies push-pull system torch has an up-down digital current adjust at your finger tip, thanks to a feeder built into the grip. The very small and light weight torch (no bulky spool-gun) enables real-time control of welding process by control of the wire feed speed and current level. The push-pull system corrects many of the problems encountered when feeding and welding soft aluminum wire, down to 0.6mm.
  • Many programmable options are available to customize the unit operation to meet most working conditions. Options include: Arc Length, 2 time, 4 time, Spot Time, Pause Time, Inductance, Burn Back, Soft Start etc. Can operate in pulse synergic, synergic, or conventional mode.

Multispot M25ALMultiSpotM25AL

High output power stud welder for aluminum, mild steel, galvanized steel, stainless steel and brass surfaces.

High output power stud welder for aluminum, mild steel, galvanized steel, stainless steel and brass surfaces.

  • Aluminum capable by using capacitor discharge technology, which delivers very brief (a few milliseconds), but very high current density (thousands of amps) to break through the surface oxidation (not fully oxidized metal) and insulation without damaging the sheet metal below.
  • Can weld up to 6mm diameter stud bolts on clean, bare (un painted) aluminum surface
  • Comes complete with a stud-gun and 2-clamp ground cables
  • User friendly information displays and control knobs.

Multispot M22 ALMultiSpotM22AL

Feature part of the new Aluminum Dent Repair Station

More car manufacturers are using aluminum as a lightweight, strong material in constructing vehicles. Aluminum has different properties than steel, requiring special tools, equipment, and processes in its repair.

  • Aluminum capable by using capacitor discharge technology, which delivers very brief (a few milliseconds), but very high current density (thousands of amps) to break through the surface oxidation (not fully oxidized metal) and insulation without damaging the sheet metal below.
  • Can weld up to 6mm diameter stud bolts on clean, bare (un painted) aluminum surface
  • Comes complete with a stud-gun and 2-clamp ground cables
  • User friendly information displays and control knobs.

 

 


Aluminum Welding

The melting temperature of the aluminum is about 660 °C while for steel is about 1500 °C. Howerver, the melting temperature of the surface oxides (alumina, Al203) is about 2000 °C, which means that surface preparation, and special care of the aluminum wire, is essential for proper welding.

Compared to steel, the aluminum thermal conductivity and thermal expansion change significantly.

  • Heat dissipation is faster; consequently the risk of sticking (lack of fusion) is greater.
  • Dilations are higher and cause more significant residual deformations.
  • Metallurgical defects, such as “hot cracking”, are possible.
  • Operational defects, such as the presence of “porosity” and “lack of fusion, are possible.”
  • Problems of joint breakthrough depend on the high fluidity of the weld pool: lap joints, or a flat supporting element, are often used.

The transfer of the filler material by pyulsed arc limits the heat input to the workpiece without decreasing the penetration of the fusion. When using the pulse, you work with a current which is on average lower than the transition value, which has the following advantages over not-inverter welders:

  • Reduced heat input on the workpiece
  • Welding of thin pieces (without changing the diameter of the wire used)
  • Better penetration
  • Reduced splatters
  • Aesthetic welds (flatter on materials such as aluminum and stainless steel)
  • Better arc control by the operator

Most OEMs today require synergic pulse technology for welding aluminum.

Double Pulse

Double pulse technology outputs high and low frequency pulses, which provides a unique welding feature over most competitors. The double pulse feature allows the weld to cool slightly during the low frequency operation. This is animportant feature when trying to weld in the vertical or overhead, horizontal positions, when the welding process may be prone to drip. In addition, the current intensity that varies between two different pulse levels, generating a bead aesthetically similar to the one obtained in TIG welding. Finally, thin pieces are deformed less due to the reduced heat transfer.

Push-Pull Torch

Chief offers a Puch-Pull torch. This small and very light weight torch has a roller built in the head of the torch which “pulls” the aluminum wire in tight control with the “push” action from the power unit. It is very difficult to feed small diameter, soft aluminum wire through a standard torch without running into many feed and control problems. Although it is ossible to feed larger diameter aluminm wire through a standard torch (as long as it has the proper line), but the length of the torch cable must be restricted. The 4 meter cable length of the Push-Pull torch enables the Chief welder to easily reach the areas to be welded. A spool gun can also be used for aluminum welding, but it is builky and is not typically tied back to the power unit for synergic control. The Push-Pull torch also comes with an up/down button for finder-tip control of wire-feed speed and current levels while welding, real-time, to adust for the weld conditions and for personal preferences. When working with aluminum, the ability to adjust the wire feed speed and current levels is important due to the fast heat condiuction of the base material, especially with the large diameter wire and the high amount of input energy.