How to Clean Aluminum oxide layer Before Welding- easy Steps

What is Aluminum oxide?

Aluminum once exposed to oxygen atmosphere will immediately forms an oxide layer which consists of amorphous Aluminum oxide (Al2O3) in 2 partial layers on top of each other, called 

  • A non-porous base or barrier layer of amorphous Al2O3 and 
  • a porous and hydrated cover layer with low crystalline contents of Al-hydroxides and Bayerite.
aluminum oxide layer

The thickness of this oxide layer grows with time, temperature and availability of Oxygen to the aluminum. Even though the oxide layer is very thin in micron, it is having a very high melting temperature of 2300° Celsius. This layer protects the Aluminum surface from further corrosion.

aluminum oxide layer

How aluminum oxide layer affects the welding of Aluminum?

  1. The density of the aluminum oxide is higher than that of aluminum metal. With iron, the oxide (rust) have a lower weight than the metal and float on the surface during fusion welding. But, with aluminum, the oxide sinks in the molten pool and may cause oxide inclusions.
  2. While aluminum melt at 660° Celsius (1220° Fahrenheit) its oxides melt at 2300° Celsius (4200° Fahrenheit). So, the oxide layer must be removed before welding to form a joint. Welded directly on oxide, will melt the aluminum before its oxide will be melted of not removed before welding.

How to remove or Clean Aluminum oxide layer Before Welding?

  1. Using AC TIG or MIG: The best way to avoid the cleaning of the oxide layer to use an AC TIG welding power source for aluminum welding. AC TIG offers a cleaning action on the aluminum surface. It is a process by which electrons remove an oxide film from the weld pool surface. The process only occurs with direct current electrode positive and the DCEP portion of alternating current. So, using AC TIG welding, you will have full flexibility to weld aluminum easily without any issue of pre-removing the aluminum oxide layer.

2. By grinding/ brushing: Oxide layer can be removed by grinding or using stainless steel wire brushes before welding. In this case, welding shall be carried out immediately otherwise new oxide layer will form on the surface and efforts of removing the oxide layer will be wasted. Use only dedicated tools for this work to avoid the contamination. Power brushing offers fast and efficient removal of oxide layer.

stainless steel wire brush

3. By pickling: Alkaline or acid pickling can be used for the aluminum oxide layer removal prior to the welding. Usually, alkaline or acid solution is applied to the part either by dipping or spraying. The oxide layers reacts with the chemical and become oxide free. In industries, pickling and passivation of aluminum parts are usually carried out after welding to increase corrosion resistance.

4. Using emery paper: Emery paper are handy and efficient for oxide removal for home use or when costly equipment’s are not available on the site. Use a 100 to 200 grit size paper to clean the surface before welding. Sanding rolls if available are also very helpful and efficient.

sanding rolls
sanding rolls

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