RE: [MW:16328] Filler wire for Aluminium to CS TIG welding

I saw your query in LinkedIn also. Aluminum could be welded to steel a couple of ways, e.g friction stir welding, explosion bonding, not certainly by Arc Welding Process. Some of the problems are as stated below.

With respect to fusion welding say, GTAW iron and aluminum are not compatible metals. Their melting temperatures differ greatly: 1220°F for aluminum vs. 2800°F for iron.
Both metals have almost no solubility for the other in the solid state, especially iron in aluminum, and several brittle intermetallic phases can form (FeAl, Fe2A1, or FeAI3)'
Consequently, resultant fusion welds joining steel and aluminum would be extremely brittle.

For the sake of fabrication your only option would braze welding or brazing. However for a heat exchanger I have doubt if Sec-IX welding qualification criteria could be met for such a joint.

Aluminum to steel combination is popular in ships, as ship super structure contains extensive Aluminum alloys for the sake of weight reductions. Friction or explosion bonded inserts are used be used as intermediatory to facilitate GTAW or GMAW. This is not the choice for process equipments e.g heat exchangers.

If the MOC aluminum on the tube side, then preferred tube-sheet would be either Aluminum or C.S Tube sheet clad with Aluminum.

Wherever C.S# Aluminum welding may occur , facilitate the design change for Aluminum to aluminum welding.

Thanks.

Pradip Goswami,P.Eng.IWE

Welding & Metallurgical Specialist

Ontario, Canada.

Email-pgoswami@sympatico.ca,

pgoswami@quickclic.net

http://www.esabna.com/us/en/education/knowledge/qa/Can-I-Weld-Aluminum-to-Steel.cfm

From: materials-welding@googlegroups.com [mailto:materials-welding@googlegroups.com] On Behalf Of Prakash Hegde
Sent: Monday, December 24, 2012 10:28 PM
To: materials-welding@googlegroups.com
Subject: Re: [MW:16322] Filler wire for Aluminium to CS TIG welding

Dear Mr Ashok

As far as I know We can not weld Aluminum to CS except Brazing

Regards

Hegde p.B.

--- On Mon, 24/12/12, Ashok Shende <shendeashok08@rediffmail.com> wrote:

From: Ashok Shende <shendeashok08@rediffmail.com>
Subject: [MW:16315] Filler wire for Aluminium to CS TIG welding
To: materials-welding@googlegroups.com
Date: Monday, 24 December, 2012, 9:32 AM

Dear experts we are having a project of aluminium heat exchangers with tube side
MOC as aluminium SB 209. Here I want to make confirm the suitable filler wires for
TIG welding of Aluminium to SA 516 GR 60/70. Thanks in advance.

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