What is the Hardest Metal to Weld?
What is the hardest metal to weld?
Whether you are a welder, project manager or someone searching for a welding service, you may be wondering if the metal you are looking at can easily be welded, without a problem. There are many different tools, tactics and techniques to get the job done, but what welding job is going to bring the most trouble? That would be aluminum! Because of aluminum’s low melting point, it can be challenging for welders to work with. This type of metal can surprisingly bring lots of frustration for various reasons. Here’s why:
Oxidation and Melting Point
Aluminum has a natural non-corrosive property, making the welding process a bit trickier than other types of metal. Aluminum oxide is created by exposure to air and water and actually sits as a top layer of the metal, causing the metal to oxidize and corrode quicker than others. This means that there will need to be a higher level of heat applied to the metal to get through that first layer. However, this can lead to unwanted holes in the aluminum underneath – so there is a very short window of workability with this metal.
Poor Heat Conductor and Fusion Region
Since aluminum is a poor heat conductor, it is more difficult to absorb heat during the welding process. This makes it hard to maintain a uniform temperature throughout the joint, resulting in a potential crack or other defects in the final product. Another issue with aluminum being a poor heat conductor is the ability to form one solid piece with two pieces. When you try to melt multiple pieces at once, it can be a challenge to get enough molten material for them to connect properly.
Impurities
As you can probably tell, aluminum is a very sensitive metal and requires extra care and attention to detail. To keep from unwanted impurities such as contamination and oxidation, there are a few easy steps that you can take:
- Thoroughly clean the metal to remove impurities and the oxidation layer
- Make sure you store the metal correctly right away to avoid any future contamination
- Keep the aluminum at room temperature to prevent oxidation
While aluminum is a difficult metal to weld, it is not impossible. Taking a few extra steps such as cleaning and properly storing the metal, can help to reduce any unnecessary trouble beforehand. At nexAir, we want our customers and employees to be properly educated, trained and equipped with everything they need to Forge Forward. Please lean on our applied industry KnowHow, and give us a call with any questions that you may have. Thank you for choosing nexAir for all of your welding and gas needs!
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Manufacturing downtime costs American companies billions annually. When production lines halt due to gas supply issues, every minute translates to lost revenue, missed deadlines, and frustrated customers. At nexAir, we've spent decades developing solutions that keep manufacturing operations running smoothly.
The Hidden Costs of Gas-Related Downtime
When manufacturers calculate downtime costs, they typically focus on labor and lost production. However, gas supply disruptions create cascading effects that multiply these losses:
- Production rescheduling that disrupts carefully optimized sequences
- Rush shipping fees to meet customer deadlines despite delays
- Quality inconsistencies when processes restart after interruptions
- Overtime costs to catch up after unplanned stoppages
- Reputation damage when delivery commitments are missed
For a typical mid-sized manufacturer, each hour of downtime represents $5,000-$10,000 in direct and indirect costs. Our analysis shows that gas-related issues cause 7-12% of total manufacturing downtime - a substantial opportunity for improvement.
From Reactive to Proactive: The Supply Continuum
Most facilities follow a predictable pattern in their gas management evolution:
Stage 1: Reactive Management At this stage, facilities order gas when they notice supplies running low or, worse, after running out. Emergencies are common, and disruptions are accepted as "part of doing business." One automotive parts supplier operating this way experienced 14 production interruptions in a single quarter.
Stage 2: Calendar-Based Management Facilities advance to scheduled deliveries based on estimated usage. While better than the reactive approach, this method still results in either excess inventory (tying up capital and space) or shortages when usage spikes occur. A plastics manufacturer following this model maintained 40% more cylinder inventory than necessary while still experiencing occasional stockouts.
Stage 3: Consumption-Based Management Our telemetry systems monitor actual gas consumption, automatically triggering orders based on usage patterns rather than calendar dates. This approach virtually eliminates both stockouts and excess inventory.
Stage 4: Integrated Supply Management The most advanced approach connects gas management directly to production planning systems. Upcoming production requirements automatically adjust supply parameters, ensuring resources are precisely aligned with needs. A medical device manufacturer using this approach reports zero gas-related downtime for 27 consecutive months while operating with minimal inventory buffers.
Our expert KnowHow™ in industrial gas applications allows us to guide customers through this evolution at a pace that makes sense for their operations.
Customizing Solutions for Maximum Uptime
Manufacturing environments vary dramatically in their gas requirements and operational constraints. We've developed flexible approaches that address these differences:
- For high-volume, consistent usage operations, our bulk systems eliminate the cylinder handling that frequently causes supply disruptions. Bulk installations include telemetry monitoring and automated ordering to prevent outages.
- For variable-demand environments, our microbulk delivery systems provide the benefits of bulk supply with lower volume commitments. These systems reduce handling requirements while maintaining the flexibility needed for changing production schedules.
- For specialized applications requiring multiple gas types, our gas management programs combine cylinder tracking, usage monitoring, and automated replenishment. This comprehensive approach ensures that specialty gases are always available when needed, regardless of how infrequently they might be used.
- For multi-site operations, our enterprise supply programs coordinate deliveries and optimize inventory across locations. By treating the organization's gas requirements holistically, we minimize both stockouts and excess inventory across the network.
This consultative approach ensures that manufacturers receive solutions aligned with their specific operational patterns rather than generic "one-size-fits-all" systems.
Beyond Traditional Supply: Integrated Services for Total Reliability
Maximum uptime requires more than just reliable gas delivery. Our integrated services address the full spectrum of gas-related reliability factors:
Equipment maintenance programs that prevent system failures before they impact production Technical gas specialists who resolve application issues that could otherwise cause production problems Safety training that prevents accidents leading to downtime events Emergency response capabilities that minimize impacts when unexpected events occur Supply chain redundancy that ensures continuity despite regional disruptions
These services complement our supply solutions to form a comprehensive reliability strategy. By addressing both everyday operations and exceptional circumstances, we help manufacturers Forge Forward with confidence that gas-related disruptions won't derail their production targets.
Measuring Success: The Results That Matter
The ultimate measure of any downtime reduction strategy is its impact on production metrics. Our manufacturing customers consistently report significant improvements after implementing our comprehensive gas management solutions:
Downtime reductions of 85-95% for gas-related issues Inventory cost decreases of 20-30% through optimized supply management Administrative time savings of 5-10 hours weekly through automated ordering and tracking Production schedule adherence improvements of 3-7% due to improved supply reliability
These performance gains translate directly to bottom-line benefits that typically deliver ROI within months rather than years. More importantly, they allow manufacturers to confidently make delivery commitments, knowing that gas supply issues won't compromise their ability to perform.
Don't let gas supply issues impact your productivity. Contact us today to explore our tailored solutions.
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