Aluminum should never be welded without using a flux because of the oxide formed. This oxide, called alumina, does not melt until a heat of 5,000° Fahrenheit is reached, four times the heat needed to melt the aluminum itself. It is necessary that this oxide be broken down or dissolved so that the aluminum may have a chance to flow together. Copper is another metal that requires a flux because of its rapid oxidation under heat.
While the flux is often thrown or sprinkled along the break while welding, much better results will be obtained by dipping the hot end of the welding rod into the flux whenever the work needs it. Sufficient powder will stick on the end of the rod for all purposes, and with some fluxes too much will adhere. Care should always be used to avoid the application of excessive flux, as this is usually worse than using too little.
SUPPLIES AND FIXTURES
Goggles.--The oxy-acetylene torch should not be used without the protection to the eyes afforded by goggles. These not only relieve unnecessary strain, but make it much easier to watch the exact progress of the work with the molten metal. The difficulty of protecting the sight while welding is even greater than when cutting metal with the torch.
Acetylene gives a light which is nearest to sunlight of any artificial illuminant. But for the fact that this gas light gives a little more green and less blue in its composition, it would be the same in quality and practically the same in intensity. This light from the gas is almost absent during welding, being lost with the addition of the extra oxygen needed to produce the welding heat. The light that is dangerous comes from the molten metal which flows under the torch at a bright white heat.
Goggles for protection against this light and the heat that goes with it may be secured in various tints, the darker glass being for welding and the lighter for cutting. Those having frames in which the metal parts do not touch the flesh directly are most desirable because of the high temperature reached by these parts.
Gloves.--While not as necessary as are the goggles, gloves are a convenience in many cases. Those in which leather touches the hands directly are really of little value as the heat that protection is desired against makes the leather so hot that nothing is gained in comfort. Gloves are made with asbestos cloth, which are not open to this objection in so great a degree.
Tables and Stands.--Tables for holding work while being welded (Figure 9) are usually made from lengths of angle steel welded together. The top should be rectangular, about two feet wide and two and one-half feet long. The legs should support the working surface at a height of thirty-two to thirty-six inches from the floor. Metal lattice work may be fastened or laid in the top framework and used to support a layer of firebrick bound together with a mixture of one-third cement and two-thirds fireclay. The piece being welded is braced and supported on this table with pieces of firebrick so that it will remain stationary during the operation.
Holders for supporting the tanks of gas may be made or purchased in forms that rest directly on the floor or that are mounted on wheels. These holders are quite useful where the floor or ground is very uneven.