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Welding Aluminum with Cored Wires S. Baumgartner1, 2, G. Posch3, H. Cerjak2 Materials Center Leoben (MCL), Franz-Josef Straße 13, A-8700 Leoben, Austria 1 2 Institute for Material Sciences, Welding and Forming, Graz University of Technology Kopernikusgasse 24, A-8010 Graz, Austria, [email protected] Böhler Schweißtechnik Austria GesmbH, Böhler-Welding-St. 1, A-8605 Kapfenberg, Austria 3 Abstract Cored wires are mainly used for GMAW of steel and nickel-base alloys. They offer lots of advantages compared to solid wires such as higher deposition rates, less spatter, improved penetration behavior and a reduced risk of lack of fusion defects. As the composition of the core can be varied easily and also the fabrication of small batches is economic, it is possible to produce various alloys aligned to the different base metals and such alloys which are not producible as solid wires. It is obvious to intend to apply these advantages also for welding aluminum. One of the main problems of welding aluminum is porosity caused by the decreasing hydrogen solubility during solidification. The use of fluxes reduces porosity and improves wettability and weld bead geometry. Using cored wires offers the possibility to put the flux inside the wire instead of applying it on the base material. This paper presents the results of bead-to-plate welds performed with different aluminum cored wires in comparison to solid wire welds. The droplet transfer is recorded with a high speed camera and the electrical data are measured simultaneously. Weld bead geometry and the tendency of porosity of cored wires and solid wires are compared with additional cross sections.