How to connect aluminum round tube: its method and principle
Aluminum round tubes are used as a common piping material for transmitting energy to humans and as a building material. Because aluminum round tubes have many advantages therefore they are used in various fields from automotive to industrial, construction to medical.
If you’ve chosen aluminum round tube for your next project, but don’t know how to connect it. The following article can help you understand the methods and tools used to connect it, as well as the principles. By following these steps you can successfully connect various types and sizes of aluminum round tubes.
1. Use of tube connectors
The use of tube connectors is an effective method of joining aluminum round tubes, and it is suitable not only for round tubes, but also for square and rectangular tubes. Most aluminum tube connectors are made of durable nylon material and are lightweight to ensure that you can do the job alone. The connectors also come in a variety of styles and sizes to match most sizes of aluminum tubing, so all you need to do is go to your local hardware store and ask the clerk for the answer.
How Tube Connectors Work:
Tube connectors work by firmly inserting opposing plugs into the ends of two or more sections of aluminum tubing. Once the tube segments are attached to the connector, a joint is formed. It can be used as a corner, right angle and pipe end.
The tools needed are:
- Aluminum tube connector
- Gauze or polishing machine
- Cutting machine or hacksaw
- Measuring tape and pen
Follow these steps to connect aluminum round tubing:
1. cut the aluminum tube to the desired length. You can do this with the help of a cutter or a hacksaw with a metal blade.
2.Use a red or black pen to mark the position of the cut before cutting, this will prevent the cut aluminum pipe from being the wrong length.
3. Use the cutter to saw the aluminum pipe, and in the process you need to clamp the pipe to prevent it from slipping away. When cutting tubes, be sure to consider whether the width of the connector used matches.
4. We get the cut aluminum tube and also need to remove the sharp edges of the aluminum tube cutout. You can use a coarse gauze cloth or a polisher to remove debris from the tube.
5. After removing the sharp edges of the tubes, insert the two aluminum tubes into the connector ends. You can push the aluminum tubes into the connector by hand until they cannot be inserted. Use a rubber mallet to hammer the connector into the aluminum tubes, making sure it fits snugly into the tubes.
6. Repeat the above steps and continue adding aluminum tubes and connectors until the frame is complete. It is important to note that some connectors require hot melt adhesive to hold the aluminum tube in place, so we should follow the instructions for selling aluminum tube connectors.
2. Connecting aluminum tubes by welding
If the aluminum tube to be connected is large or if you cannot find a connector that matches the size. Then we can connect them by soldering the ends of the aluminum round tubes. It is important to note that this method can be complicated and dangerous, as soldering can burn our skin and hair.
Tools needed for this method:
- Argon arc welding torch, liquefied gas welding torch, etc.
- Organic solvents such as acetone, gasoline (for degreasing)
- Wire brush, polishing agent, etc.
- Welding wire, pads (such as graphite plate, stainless steel plate, etc.)
- Heating furnace (for preheating aluminum tubes)
- Thermometer
Belows video shows welding process for aluminum tube：
Methods and steps for welding
1. Thoroughly remove the oxide film and oil on the surface of the aluminum tube weld bead and wire. This can be achieved through chemical cleaning or mechanical cleaning.
2. Design the joints:
According to the size and shape of the aluminum tube to be connected, design a suitable joint to ensure that the gap between one side of the joint is controlled within a suitable range, usually 0.08 ~ 0.2mm, and the length of the welded seam is generally not more than 30mm.
3. Preheat the aluminum tube to be welded:
For aluminum tubes with large thickness (e.g. 10mm ~ 15mm), preheating before welding may be required, and the preheating temperature is usually 100℃ ~ 200℃ to reduce defects such as deformation and porosity.
4. Weld the ends of the aluminum tube:
Use appropriate welding tools (e.g., special torch for hydrogen-oxygen flame, argon arc welding torch, etc.) to ignite the flame, and adjust the flame size and position to ensure that the flame can evenly heat the welding area. Aim the flame at the welding area and heat it evenly to the proper temperature. Make the two ends of the aluminum tube melt and then join together.
5. Polishing the aluminum tube upon completion
The finished aluminum tube needs to be polished and wiped down because the weld pattern is uneven, so the raised surface needs to be smoothed out. Polishing the aluminum tube welds reduces friction and improves overall strength.
Points to note:
- When choosing the connection method, comprehensive consideration needs to be made according to the material, specification, use environment and connection requirements of the aluminum tube.
- No matter which connection method is used, safety needs to be ensured. It is recommended that you look for a professional manufacturer to do the job for your safety.
Hugh Aluminum helps you connect aluminum tubing!
Hugh Aluminum has an excellent welding team. We have 14 years of experience specializing in welding and can help you with this project.
In addition, we are a large aluminum extrusion manufacturer. We can meet your needs from designing to manufacturing all types of aluminum tubes, whether they are welded or extruded. Our team can help you with all of them!
