Skilled Welder Akira Miki, a Self-Taught Aluminum Welding Expert (Continuation)
In the world of automotive manufacturing, Akira Miki stands out as a senior expert, having honed his skills in aluminum welding since 2018. As a member of the Monozukuri Development Management Division, Skills Training Promotion Group, Miki demonstrates press mold buildup welding, a skill essential to car manufacturing.
Aluminum, with its specific gravity one-third that of iron, presents unique challenges due to its physical and chemical properties. Its high thermal conductivity causes heat to dissipate quickly, necessitating higher heat input and preheating to ensure strong welds. The thin oxide layer on aluminum melts at a higher temperature than the base metal, requiring alternating current (AC) in TIG welding to clean the oxide and achieve proper fusion.
Miki, a self-taught welder, believes that the ability to visualize the pool is crucial for being a good arc welder, and this ability is largely a matter of natural aptitude. He uses his senses of sight, hearing, smell, and touch to gauge the condition of the molten metal pool during the welding process.
The steel plate and welding rod melt at temperatures of 5,000 to 6,000°C during the welding process, while aluminum melts at around 600°C. This enormous difference from steel welding was a challenge Nakamoto, another welder, once struggled with. However, Miki demonstrated aluminum welding along with Nakamoto, sharing his techniques and tips.
Commonly used techniques for self-taught aluminum welding at high temperatures in car manufacturing include TIG (GTAW) welding with AC current and 100% argon shielding gas, using a pure tungsten electrode and proper filler rods, preheating the aluminum, applying heat sinks or clamps, thoroughly cleaning the aluminum surface before welding, feeding filler metal manually, and employing online tutorials, videos, and communities for practical advice.
Miki has been training young welders from all over the world at the Motomachi Plant Monozukuri Staff Development Center since 2008. One of his works is an aluminum plate on which he has welded "Toyota Times" in Japanese. After welding, Miki uses a wire brush to knock away coarse black slag from the welded section.
For beginners, Miki provides clear, simple instructions, but becoming a skilled welder requires planning out how to adjust current and rod angle to control the pool of molten metal. The welding process involves the use of heat-resistant clothing, gloves, a helmet, and adjusting the dials on a welder. Miki's aluminum welding is as perfectly finished as his steel welding, showcasing his mastery of the craft.
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- In the realm of self-taught aluminum welding, Miki seamlessly integrates technology by referencing online tutorials, videos, and welding communities to refine his techniques.
- Miki's lifestyle, marked by diligence and a passion for sports, is evident in his teachings, as he encourages young welders to embrace challenges and always strive for excellence, much like an athlete training for a competition.
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