Removing Warping In Aluminum Sheet Metal

The warping of metal during the welding process is due to the high levels of heat involved.

Removing warping in aluminum sheet metal. Long story short the sides have to be welded together to make a full side. Then as the bead cools and solidifies it contracts but by this time the metal pieces are fused together. This restraint creates high residual tensile stress that causes the weld to act like a stretched rubber band with the workpiece holding the ends figure 1 for this reason when the clamps that hold the workpiece are removed the base metal is allowed to move or spring. The weld wants to shrink as it cools to room temperature but is restrained from doing so by the adjacent cold base metal.

In the process heat is applied to certain spots on the convex side of the warped metals. Use anti warping devices and techniques. When welding steel this weld bead is laid down at around 2 500 f 1 370c. A 5356 filler metal also works for 5052 materials specifically.

Then bend the sheet back and forth a few times to snap it. The more time the arc is in an area the hotter it. Typical aluminum alloys for sheet fabrication are 3003 and 5052. An ounce of prevention the battle between hot cold.

I started welding one side today a 15 piece to a 48 piece 77 5 long. When i experimented sandblasting etched designs into plexi glass plastic acrylic glass with aluminum oxide abrasive i noticed it actually start to melt the plastic. Thermal correction of metal warping is premised on the idea of creating local stress that is high enough to pull back the metal warped back to shape during cooling. Techniques for welding sheet metal.

That heat spreads out making the metal expand. To prevent burn through and warping don t whip or weave the torch. Spot heating is ideal for removing warping in your thin metal sheets. Arc welding mig and tig entails fusing a filler metal with the materials being joined.

Even seasoned pros who perhaps haven t had a serious issue with a warped piece of sheet metal in a long time can gain new insight from some of these tips. And you can use the same technique anytime you need a straight cut on aluminum or other light gauge sheet metal even steel. Filler metals for either of these would be 4043 or 4943.