Welded Connections
PDU recommends the following welding methods for installing aluminum weldment fittings to aluminum bus pipe and/or aluminum wire:
Welding Apparatus: TIG or MIG
Filler rod (welding wire): 4043 aluminum alloy
Shielding Gas: Argon, Helium or combination of both
Welded Cable connections
- Remove all oxides, grease, oil, and moisture from the surfaces that are to be welded. Clean the welding surfaces of both the conductor and the connector by brushing vigorously with a stainless steel brush.
- Slide the conductor into the weldment cavity of the connector until it is within 1/8” to 3/16” of the rear of the cavity.
- Before welding the connection, a test weld should be made on an aluminum casting to check weld settings.
- Begin welding the inner wall of the casting and moving toward the center of the conductor.
- Wire brush the original weld if more than one pass is needed.
Welded Tubular connections
- Remove all dirt, grease, oil, and moisture from the surfaces that are to be welded. Clean the welding surfaces of both the conductor and the connector by brushing vigorously with a stainless steel brush.
- Before welding the connection, a test weld should be made on an aluminum casting to check the weld settings.
- It is recommended that the tubular bus be positioned in the weldment cavity and tack welded before final welding.
- Begin the final weld by burning into the original weld then passing over the entire contact surface.
- When possible welds should encompass entire perimeter of connector, excluding bus supports and end plugs where tack welds may be sufficient.
Note: The final judgment of any welding should always be left to the project supervisor and/or engineer.
