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Home › Products › Connectors › Distribution › Standard Voltage › Reference Data › General Welding Specifications

General Welding Specifications for Consumable Electrode Welding Method

Scope:

 

This specification applies primarily to welded aluminum connectors for substation construction.

Material:

Castings

 

As furnished by Anderson are molded from 356 aluminum alloy and heat treated to T6 condition, or #99 pure aluminum depending on the application.

Filler Rod

 

043 aluminum alloy 1/16" diameter for all joints as shown in the Anderson catalog.

Shielding Gas

 

Argon.

Welding Apparatus

 

Tungsten-arc (TIG) or metallic-arc inert-gas shielding(MIG).A 400 amp welding machine with reverse polarity is capable of handling the majority of aluminum welding jobs.

Procedures:

 

It is of the utmost importance to remove oil, grease, water and oxide from the surfaces to be welded. All surfaces to be welded should be wire brushed with a stainless steel brush prior to welding. If more than one weld pass is requ*ed, the original weld should be wire brushed before applying additional weld.

Pre-heating of surfaces to 400° E is optional, but by preheating the surfaces before welding it is possible for the operator to weld easily and faster.

Metallic-Arc Inert-Gas Consumable Electrode

IPS Size	Wall Thickness	Amperes	4043 Filler Rod Size	Approx. Argon Flow CFH	Preheat °F	Wire Speed Inches Per Min.	No. Passes
1/2	.108	125-150	1/16	20	None	170	1
3/4	.113	125-150	1/16	20	None	180	1
1	.133	125-150	1/16	30	None	180	1
1-1/4	.140	160-170	1/16	30	None	180	1
1-1/2	.144	160-170	1/16	30	None	180	1
2	.154	170-190	1/16	30	None	180	1
2-1/2	.203	170-190	1/16	40	None	180	1
3	.216	170-190	1/16	40	Optional to 400° F	180	1
3-1/2	.226	170-190	1/16	40	Optional to 400° F	200	1
4	.237	180-200	1/16	50	Optional to 400° F	200	1
4-1/2	.247	180-200	1/16	50	Optional to 400° F	200	1
5	.258	180-200	1/16	50	Optional to 400° F	200	1 or 2
6	.280	180-200	1/16	50	Optional to 400° F	200	1 or 2

Flat Bar

Flat Bar Thickness	Amperes	4043 Filler Rod Size	Approx. Argon Flow CFH	Preheat °F	Wire Speed Inches Per Min.
1/8	125-150	1/16	30	None	180
1/4	180-200	1/16	50	Optional to 400° F	180
3/8	300	1/16	50	Optional to 400° F	200
1/2	340	1/16	60	400° F	200
3/4	375	1/16	60	400° F	200

Tungsten-Arc

IPS Size	Wall Thickness	Amperes	Gas Cup Dia. Inches	Tungsten Dia. Inches	Argon Flow CFH	Preheat °F	No. Passes	4043 Filler Rod Size
1/2	.108	125-150	3/8	1/8	20	None	1	1/8
3/4	.113	125-150	3/8	1/8	20	None	1	1/8
1	.133	125-150	3/8	1/8	30	None	1	1/8
1-1/4	.140	160-170	3/8	1/8	30	None	1	1/8
1-1/2	.144	160-170	3/8	1/8	30	None	1	1/8
2	.154	170-190	1/8	1/8	30	None	1	3/16
2-1/2	.203	170-190	1/2	3/16	40	None	1	3/16
3	.216	170-190	1/2	3/16	40	Optional to 400° F	1	3/16
3-1/2	.226	170-190	1/2	3/16	40	Optional to 400° F	1	3/16
4	.237	180-200	1/2	3/16	50	Optional to 400° F	1	3/16
4-1/2	.247	180-200	1/2	3/16	50	Optional to 400° F	1	3/16
5	.258	180-200	1/2	3/16	50	Optional to 400° F	1 or 2	3/16
6	.280	180-200	1/2	3/16	50	Optional to 400° F	1 or 2	3/16

Flat Bar

Flat Bar Thickness	Apmeres	Gas Cup Dia. Inches	Tungsten Dia.	Argon Flow CFH	Preheat °F	No. Passess	4043 Filler Rod Size
1/8	125	3/8	1/8	30	None	1	1/8
1/4	150	1/2	3/16	30	None	1	3/16
3/8	300	1/2	3/16	50	Optional to 400° F	1	1/4
1/2	400	5/8	1/4	50	400° F	1 or 2	1/4
3/4	450	5/8	1/4	500	400° F	2	5/16
1	500	5/8	5/16	50	50	2	5/16