Aluminium welding
Drifting
Joined: Sep 2006
Posts: 1,986
Likes: 21
From: Columbus MN
Do you mean aluminum wire (instead of rods)? Aluminum wire can be trick to keep free in a welder with the spool inside the welder. Here are some aluminum welding tips I found online when I was learning to use my MIG welder:
1. The best feeding of wire for aluminum is done with a spool gun. If you can’t use a spool gun, use the shortest gun possible and keep the gun as straight as possible. Use Argon only for shielding gas. Only use a push gun technique when welding aluminum.
2. If you are having feeding problems, one thing you can try is a contact tip that is one size bigger than your wire.
3. The most common wire type is ER4043 for all-purpose work. ER5356 is a stiffer wire (easier to feed), and is used when more rigid, higher-strength weld properties are needed.
4. Clean the aluminum before welding, to remove the oxide layer. Use a stainless steel wire brush used only for cleaning aluminum.
5. Fill the crater at the end of the weld to avoid a crack. One way to do this is to dwell in the weld pool for a second at the end of the weld.
1. The best feeding of wire for aluminum is done with a spool gun. If you can’t use a spool gun, use the shortest gun possible and keep the gun as straight as possible. Use Argon only for shielding gas. Only use a push gun technique when welding aluminum.
2. If you are having feeding problems, one thing you can try is a contact tip that is one size bigger than your wire.
3. The most common wire type is ER4043 for all-purpose work. ER5356 is a stiffer wire (easier to feed), and is used when more rigid, higher-strength weld properties are needed.
4. Clean the aluminum before welding, to remove the oxide layer. Use a stainless steel wire brush used only for cleaning aluminum.
5. Fill the crater at the end of the weld to avoid a crack. One way to do this is to dwell in the weld pool for a second at the end of the weld.
Burning Brakes
Joined: Feb 2004
Posts: 758
Likes: 14
From: Ville de la Baie Quebec. A winner is just a loser who tried again.
Theoretically yes,,, alluminum wire and gaz, welding alluminum needs a differant approach, it is very sensitive to impuraties like carbon, oil, corrosion, so a good prep is needed, and even this may not be enough, an intake is cast allu, this means garbage within the alluminum itself. This is not to say it is not weldable, just a little more demanding than steel. Personally I would get it tigged,, because you have more control on what your doing, this compansates with difficult materials. Give it a try,, and you can always have it done afterwards if it dos'nt work out.
Burning Brakes
Joined: Dec 2002
Posts: 1,069
Likes: 2
From: Sherwood Park AB
You may need a spool gun. Aluminum Mig needs a very quick wire speed. I have always heard that aluminum is very difficult to weld. The melting temp is relatively low and it doesn't change color before it melts. I agree with getting it Tig welded.
I had a crack in my bellhousing, I took it to a river boat builder. He charged me $15 and even ground the outside down perfectly.
I had a crack in my bellhousing, I took it to a river boat builder. He charged me $15 and even ground the outside down perfectly.
Melting Slicks
Joined: Jul 2007
Posts: 3,352
Likes: 1
From: Westminster Maryland
Take it to a weld shop. I have a tig and a mig unit, and I still take my cast aluminum to a shop. The prep to clean cast aluminum is 99% of the job. A shop will have experience in prepping and preheating to the right temp for the weld to knit. My $.02.
Burning Brakes
Joined: Nov 2005
Posts: 1,109
Likes: 2
From: Marengo Illinois
Cruise-In VIII Veteran
St. Jude Donor '06
I've been welding aluminum for 23 years (mig and tig)
All of the above tips are great, but welding aluminum is tricky and you could make a mess of your intake very quickly.
With the time you'll spend getting it right, wouldn't it be easier to pay an experienced welder $25-$50 to get it right the first time?
And I would go with tig, I have seen pin holes and porosity problems with mig which would definitely cause problems with an intake.
Just my $.02 good luck.
Tim
All of the above tips are great, but welding aluminum is tricky and you could make a mess of your intake very quickly.
With the time you'll spend getting it right, wouldn't it be easier to pay an experienced welder $25-$50 to get it right the first time?
And I would go with tig, I have seen pin holes and porosity problems with mig which would definitely cause problems with an intake.
Just my $.02 good luck.
Tim
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Racer
Joined: Aug 2007
Posts: 366
Likes: 2
From: deptford New Jersey
aluminum welding
I would recomend having it tig welded. You can get away with mig but chances are you will not get the apperance that you are looking for.
If you prep and preheat before tig welding. You can really get a first class job. ( and it will be done right the first time)
I would check with a local weld /machine shop. I use to do a lot of side work in my welding days. You could probaly get it done on the side for $20
Good luck
If you prep and preheat before tig welding. You can really get a first class job. ( and it will be done right the first time)
I would check with a local weld /machine shop. I use to do a lot of side work in my welding days. You could probaly get it done on the side for $20
Good luck
Instructor
Joined: Oct 2007
Posts: 189
Likes: 0
From: Quebec Canada
Theoretically yes,,, alluminum wire and gaz, welding alluminum needs a differant approach, it is very sensitive to impuraties like carbon, oil, corrosion, so a good prep is needed, and even this may not be enough, an intake is cast allu, this means garbage within the alluminum itself. This is not to say it is not weldable, just a little more demanding than steel. Personally I would get it tigged,, because you have more control on what your doing, this compansates with difficult materials. Give it a try,, and you can always have it done afterwards if it dos'nt work out.
