Professional welding of aluminum alloys requires not only expensive equipment, but also carefully selected consumables that can provide a stable arc and no porosity. One of the most popular solutions in the Russian market is aluminum-wire domestic production, developed specifically for work with pulsed current sources in synergetics mode.
Model Solaris Alumig 230dp Synergy is a high-tech product created for the connection of structures made of aluminum-magnesium alloys, such as AMG and AMG6. Its uniqueness lies in the optimized chemical composition, which allows you to minimize spraying and provide a smooth roller of the seam even when working at high currents.
In this article, we will analyze in detail the technical features of this material, consider compatibility with various welding equipment and provide practical recommendations for setting the parameters to achieve an ideal result.
Chemical composition and physical and mechanical properties
The wire base Solaris Alumig 230dp Synergy is an alloy Al-Mgwhere magnesium is the main alloying element. Magnesium is responsible for increasing the strength characteristics of the seam and its resistance to corrosion in aggressive environments, which is critical for shipbuilding and the aviation industry.
The magnesium content of this material is strictly controlled and usually varies within the range of 4.7–5.5%which meets the standard ER5356. This balance ensures excellent plasticity of the compound and reduces the risk of hot cracks when the metal cools.
An important aspect is the purity of the alloy. The composition minimized the amount of impurities of iron and silicon, which could adversely affect the conductivity and stability of the combustion of the arc. This is especially important when using automated systems, where the slightest deviation can lead to marriage.
The influence of manganese on the structure of the seam
Adding manganese to the alloy (about 0.1%) contributes to the formation of dispersed particles that prevent the growth of grain in the zone of thermal influence, preserving the viscosity of the metal.
The mechanical properties of the fused metal allow to withstand significant dynamic loads. The tensile strength limit is at least 290 MPa, and the relative elongation reaches 18-20%, which indicates a high ability of the material to deform without breaking.
Equipment compatibility and Synergy modes
abbreviation Synergy The name indicates that the wire is designed to work with inverter current sources equipped with special programs for aluminum welding. Such devices automatically select the ratio of current and wire supply speed.
The most effective use Solaris Alumig 230dp Synergy It is used with equipment that supports impulse-welding (Pulse) In this mode, the current periodically rises to peak values, which allows you to tear off a drop of molten metal strictly at the moment of maximum, providing transfer without short circuit.
Use the Double Pulse mode for welding thick aluminum profiles - this will create the effect of "scaly" seam, characteristic of argono-arc welding, and improve the removal of gases.
Modern semi-automatics allow the operator to select the type of material in the menu, after which the electronics itself sets the basic parameters. However, fine-tuning for a particular task often requires manual correction of inductance or cycle length.
When working with this wire, it is recommended to use burners with a feed channel equipped with a Teflon liner. This reduces friction of the soft aluminum bar against the channel wall and prevents the formation of a "beard" at the end of the wire, which can cause sticking.
- 🔹 Ideal for devices with synergistic control
- 🔹 Requires the use of an inert gas (argon or helium)
- 🔹 Recommended diameter of the contact tip - 0.2-0.3 mm more than the diameter of the wire
- 🔹 Stable when operating in the current range from 80 to 350 Amps
Welding technology and setting parameters
To obtain a high-quality connection, it is necessary to strictly observe the technology of preparation and configuration of equipment. Aluminum has a high thermal conductivity, therefore, welding They should be designed to provide fast heating without burns.
In the case of Solaris Alumig 230dp Synergy The key parameter is the departure of the wire. The optimal distance from the cut-off tip to the product is within 12-15 mm. An increase in the departure will lead to instability of the arc, and a decrease will lead to overheating of the contact tip.
☑️ Semi-automatic setup
The gas supply rate should be sufficient to protect the welding bath from oxidation, but not excessive, so as not to cause turbulence of the flow and air sucking. For most standard burners, the argon consumption is 10-14 liters per minute.
The table below shows the approximate welding modes for different metal thicknesses when using this wire. Remember that the exact values can vary depending on the design of the joint and the position in the space.
| Metal thickness, mm | Wire diameter, mm | Current power, A | Voltage, B | Gas flow rate, l/min |
|---|---|---|---|---|
| 2.0 - 3.0 | 1.0 | 90 - 120 | 18 - 20 | 10 - 12 |
| 3.0 - 5.0 | 1.2 | 140 - 180 | 21 - 23 | 12 - 14 |
| 5.0 - 8.0 | 1.2 | 200 - 250 | 24 - 26 | 14 - 16 |
| 8.0 - 12.0 | 1.6 | 280 - 320 | 27 - 29 | 16 - 18 |
Particular attention should be paid to the angle of inclination of the burner. When welding aluminum, it is recommended to conduct a burner at an angle. 10-15 degrees. In the direction of movement (the way of "a corner forward"). This provides better visualization of the bath and protection with gas.
Removal of defects and typical problems
Even with the use of quality materials, such as Solaris AlumigA violation of technology can lead to defects. The most common problem is the porosity of the seam caused by the presence of moisture or contaminants on the metal surface.
⚠️ Aluminum is instantly oxidized in air. Mechanical cleaning of the edges should be carried out immediately before welding, not earlier than 1-2 hours before the start of work.
Another common problem is the indigestion of the roots of the seam. This is due to insufficient current or too high welding speed. In synergistic mode, it is necessary to increase the current correlation or reduce the speed of movement of the burner.
If there is a strong splashing, check the purity of the contact tip and the state of the current supply. Also, the cause may be too long arc or an incorrect balance between background and pulse current.
Why does a “hot” crack occur?
Cracks often appear when welding rigidly fixed parts or when using wire with the wrong composition for a particular base metal alloy.
To correct the cuts, you should change the angle of inclination of the burner or reduce the arc voltage. Cuts weaken the cross section of the seam and are stress concentrators, so their presence is unacceptable in responsible designs.
Surface preparation and storage of consumables
The quality of the welded connection directly depends on the preparation of the edges. Aluminum alloys of the series AMG They are often covered with refractory oxide film, which must be removed. Mechanical cleaning with a stainless brush or shaber is a mandatory stage.
Wire storage Solaris Alumig 230dp Synergy It also requires that certain rules be followed. The coves must be in the original sealed packaging until the time of use. After opening, the coil is recommended to be stored in a dry room with low humidity.
- 🧼 Degreasing the edges with acetone or alcohol before welding
- 🧹 Use of a separate brush for aluminum only (without traces of steel)
- 🌡️ Heating thick-walled parts to 150-200 ° C to remove moisture
- 📦 Sealing of an open bay with polyethylene at long breaks
Moisture that gets to the surface of the wire or in the welding zone, instantly breaks down into hydrogen and oxygen. Hydrogen, dissolved in molten aluminum, when cooled, forms pores that cannot be removed without digesting the seam.
Surface cleanliness and lack of moisture is 90% of the success of welding aluminum. No amount of current adjustment will save the seam from pores if the edges are dirty.
Application areas and cost-effectiveness
Wire Solaris Alumig 230dp Synergy It has found wide application in various industries. Due to its good mechanical properties, it is used for the manufacture of truck bodies, tanks for the transportation of chemicals and fuel tanks.
In shipbuilding, this material is indispensable for the assembly of hulls of high-speed boats and yachts, where a combination of lightness of construction and high corrosion resistance is required. It is also used in construction for the installation of aluminum facades and structures.
From an economic point of view, the use of domestic wire allows you to reduce the cost of work compared to imported analogues, without sacrificing quality. The stability of the welding process reduces the percentage of defect and gas consumption.
⚠️ Note: It is not recommended to use magnesium wire for welding alloys containing silicon (e.g. silimins) due to the risk of forming brittle intermetallic compounds.
Choice in favour Solaris Alumig 230dp Synergy It is justified both for large production lines and for small workshops specializing in working with non-ferrous metals. This is a universal solution for most tasks.
Frequently Asked Questions (FAQ)
Can Solaris Alumig 230dp Synergy alloys of series D (duraluminum) be cooked with wire?
Welding of duraluminium alloys (e.g., D16) wire AMG It is possible, but the seam will have less strength than the base metal, since duraluminum is strengthened by heat treatment, which is broken in the seam zone. For responsible structures of duraluminium, it is better to use the wire system Al-Cu-Mg (e.g., 1554 or 1570), if technology permits, or to tolerate a strength factor of 0.5-0.6.
Which gas is better to use: pure argon or a mixture with helium?
For thicknesses up to 6-8 mm, pure high-purity argon is sufficient (99.998%). The addition of helium (up to 30-50%) is justified when welding thick-walled parts (more than 10 mm), since helium increases the arc temperature and increases the depth of the cooker, but at the same time increases the cost of work and requires more powerful equipment.
Why does the wire always stick in the contact tip?
The main causes of sticking: too small a flight of the wire, wear of the contact tip (the diameter of the hole has increased), insufficient arc voltage or the presence of an oxide film on the wire. Also check the pressure in the feeding mechanism – if the rollers compress the soft aluminum too much, it will warp and get stuck in the channel.
Do I need to preheat the part before welding this wire?
Preheating is only necessary for metal thicknesses above 10 mm or when operating in low ambient temperatures. For thin-walled structures (up to 4 mm) heating is not required and can lead to burnout. The interpass control temperature should not exceed 80-100°C to preserve the properties of the alloy.