Use and Care Manual
77
GMAW
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Welding Guidelines for Aluminum GMAW
Fillet and Lap Welding — Flat, Horizontal, Vertical and Overhead
Welding Argon Approx.
Electrode Current
(4)
Arc Gas Flow Travel Speed Electrode
Plate Weld Weld Diameter (Amps) Voltage
(4)
CFH ipm Consump.
Thickness
(1)
Position
(2)
Passes
(3)
In. (mm) (DC+) (Volts) (L/min.) (M/min.) (lbs/100 ft)
3/32”
F, V, H, O 1
0.030
100-130 18-22
30 24 - 30 1.8
(2 mm) (0.8) (14) (0.60 - 0.76)
1/8”
F1
0.030 - 3/64
125-150 20-24
30 24 - 30 2
(3 mm) (0.8 - 1.2) (14) (0.60 - 0.76)
V, H 1
.030
110-130 19-23
30 24 - 30 2
(0.8) (14) (0.60 - 0.76)
O1
0.030 - 3/64
115-140 20-24
40 24 - 30 2
(0.8 - 1.2) (19) (0.60 - 0.76)
3/16”
F1
3/64 180-210 22-26 30 24 - 30 4.5
(5 mm) (1.2) (14) (0.60 - 0.76)
V, H 1
0.030 - 3/64
130-175 21-25
35 24 - 30 4.5
(0.8 - 1.2) (16) (0.60 - 0.76)
O1
0.030 - 3/64
130-190 22-26
45 24 - 30 4.5
(0.8 - 1.2) (21) (0.60 - 0.76)
1/4”
F1
3/64 - 1/16
170-240 24-28
40 24 - 30 7
(6 mm)
(1.2 - 1.6) (19) (0.60 - 0.76)
V, H 1
3/64
170-210 23-27
45 24 - 30 7
(1.2) (21) (0.60 - 0.76)
O1
3/64 - 1/16
190-220 24-28
60 24 - 30 7
(1.2 - 1.6) (28) (0.60 - 0.76)
3/8”
F 1
1/16
240-300 26-29
50 18 - 25 17
(10 mm) (1.6) (24) (0.46 - 0.64)
H, V 3
1/16
190-240 24-27
60 24 - 30 17
(1.6) (28) (0.60 - 0.76)
O3
1/16
200-240 25-28
85 24 - 30 17
(1.6) (40) (0.60 - 0.76)
3/4”
F 4
3/32
360-380 26-30
60 18 - 25 66
(19 mm) (2.4) (28) (0.46 - 0.64)
H, V 4-6
1/16
260-310 25-29
70 24 - 30 66
(1.6) (33) (0.60 - 0.76)
O 10
1/16
275-310 25-29
85 24 - 30 66
(1.6) (40) (0.60 - 0.76)
(1)
Metal thickness of 3/4” or greater for fillet welds sometimes employ a double vee bevel of 50° or greater included vee with 3/32” to 1/8” land thickness on the abutting
member.
(2)
F = Flat; V = Vertical; H = Horizontal; O = Overhead.
(3)
Number of weld passes and electrode consumption given for weld on one side only.
(4)
For 5xxx
series electrodes, use a welding current in the high side of the range and an arc voltage in the lower portion of the range. 1xxx, 2xxx and 4xxx series electrodes would use
the lower currents and higher arc voltages.