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Aluminium Welding

We have a long history of development of welded aluminium products from a wide range of market sectors. The highly skilled and experienced aluminium welders are involved with the customer at the early stages of the design of new profiles or on established products to value engineer the process to meet customer requirements.

Welded aluminium

Did you know?

Welding makes it possible to make high quality, high strength welds at high speeds, in all positions, without corrosive fluxes

Hydro’s expertise in welded aluminium assemblies can be demonstrated across our industry. Whether it is MIG aluminium welding, TIG aluminium welding, Friction Stir Welding or CMT aluminium welding Hydro can offer the best solution for the project in house.

Hydro fabrication tailor Weld Procedure and Welder Approvals for Specific Customer Products and Welding services are carried out in accordance with BS EN 1011 parts 1 & 4. 

When this is required we can carry out these Procedure Developments and obtain Procedure Approvals to BS EN 15614 -2 or BS EN 15613 ( Pre Production Parts ) and subsequently obtain Welder Approvals to BS 9606-2 to cover this work.

Hydro Fabrication have Welders Trained to Level 2 in Visual and Penetrant Inspection in accordance with BS EN ISO 9712 through British Institute of None Destructive Testing.

During the production stages the following standards can be applied following development and agreement with customers to meet their requirements:

  • Penetrant Testing to BS EN ISO 3452 – 1.
  • Visual Inspection to BS EN ISO 17637.

Coded  Aluminium Welding

Hydro are able to offer coded welding of aluminium from our Bedwas facility. Our welders become coded to your specific job requirements and produce samples that mirror your required exact welding configuration. The process by which we approve a coded welder is through a welder approval test and once complete our welder can produce coded welding to your specific ISO standard.

The advantages of using Friction Stir Welding (FSW) – What is Friction Stir Welding?

Fusion  Aluminium Welding Services

Hydro fabrication offer the following fusion welding services:

TIG  Aluminium Welding Capabilities

  • Combinations of 1000, 3000, 5000 and 6000 Series Alloys.
  • Metal Thicknesses from 1mm to 13 mm for Fillet Welds.
  • Metal Thicknesses from 1.5 mm to 6.5 mm for Butt Welds

The overall benefits are:

  • High cosmetic finish due to minimal contamination
  • Process thin gauge material efficiently
  • High control of process
  • High precision of weld

Tig welding UK.jpg

MIG  Aluminium Welding Capabilities

  • Combinations of 1000, 3000, 5000 and 6000 Series Alloys.
  • Metal Thicknesses from 3mm to 25mm for Fillet Welds.

The overview of the benefits are:

  • Comparable low-cost solution
  • Higher speed of process
  • Used for difficult to access areas
  • Process heavy gauge material

Aluminium specialist welding UK

CMT welding (Cold Metal Transfer)

The capabilities of CMT welding are:

  • Combinations of 1000, 3000, 5000 and 6000 Series Alloys.
  • Metal Thicknesses from 1.2mm to 19mm for Fillet Welds.

The overview of the benefits are:

  • increasing the manufacturing speed and efficiency
  • The quality of the assembly is improved due to the reduced heat input and the stability of the arc.
  • Post welding operations are also reduced such as linishing or polishing and a higher quality part can be produced


  • EN1090
  • CE Certified
  • BS EN 1011
  • BS EN 9606-2

We currently supply aluminium welding in assemblies throughout the following industries:

  • Leisure (Caravans, Motorhomes, Campervans)
  • E.V (battery enclosures, charging points)
  • Automotive (bumper beams, cant rails, strut braces, seal carrier, roof rails)
  • Aerospace (Seats, baggage bars, spars)
  • Medical (Medical trollies, ceiling hoists)
  • Architectural (Balconies, Balustrading, Facades, Louvers, windows)
  • Rail (Window frames, Cabin Components, seats, door frames)

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