Skilled Aluminum Welder Akira Miki Continues Impressive Journey Without Formal Training (Second Installment)
At the Monozukuri Staff Development Center, master welder Akira Miki showcases his astounding works of art produced through his welding skills. Miki, a renowned figure in the automotive industry, specializes in press mold buildup welding, a skill essential to car manufacturing.
Miki's aluminum welding demonstration was guided by him, resulting in no melt-through and a superb finish. This is no small feat, given the unique challenges associated with self-taught aluminum welding. Aluminum's high thermal conductivity rapidly dissipates heat, and the presence of a tough oxide layer that melts at a much higher temperature than the base metal makes it difficult to achieve proper penetration without burning through or creating weak welds.
Miki addresses these challenges by adjusting the electric current levels, rod material, and angle to control the welding process. He believes that the feeling of welding aluminum is totally different from steel. In fact, he 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.
The welding process involves the use of temperatures over 5,000 degrees Celsius. To avoid warping or burn-through, techniques include preheating the aluminum, using heat sinks, and carefully balancing the welding parameters like current, frequency, and shielding gas flow (typically 100% argon).
Rigorous surface preparation is another key factor. Thorough degreasing and oxide removal right before welding using solvents and dedicated stainless steel wire brushes prevent contamination and ensure a clean surface.
Miki's aluminum plate work, which reads "Toyota Times" in Japanese, leaves those with welding knowledge speechless. His exceptional temperature control and weld precision are beyond standard formal methods.
Miki has been teaching aluminum welding since 2018 and has been training young welders from all over the world at the Motomachi Plant Monozukuri Staff Development Center since 2008. He dons heat-resistant clothing, gloves, and a helmet during the welding process.
Shigeru Nakamoto, a steel sheet welding expert and Miki's named successor, still struggles with aluminum welding. This highlights the personal, experience-driven approach required to master aluminum welding, a skill that is increasingly essential due to automotive electrification. Aluminum has a specific gravity 1/3 that of iron, making it lighter and more efficient for electric vehicles.
In summary, the uniqueness of self-taught aluminum welding mastery in the automotive industry lies in overcoming aluminum’s metallurgical challenges through a personal, experience-driven approach to controlling heat, cleanliness, and welding technique, commonly using AC TIG welding as the optimal process.
Miki's expertise in aluminum welding, a crucial skill in the automotive industry, is highly sought after, as evidenced by his employment at the Motomachi Plant Monozukuri Staff Development Center since 2008. He has since trained numerous young welders from various backgrounds. The finance industry recognizes the value of Miki's skills, offering him opportunities to share his knowledge through technology platforms, such as webinars and online courses, contributing to education and self-development in the field of career development and skills training. As the automotive industry transitions towards electrification, the need for skilled aluminum welders like Miki will continue to grow, given aluminum's lightweight and efficient properties for electric vehicles.
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