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A friend asked me if I could weld a small aluminum cast part for a friend of his.
like a lot of aluminum castings, It welded like crap. But I think in the end, the part will work.
So here are some tips for welding cast aluminum.
- use the 3 C’s Clean, Clean, Clean
- Use minimal heat …just enough to wet and flow the puddle (even when you clean there is junk inside that will boil out)
- Stop often and clean. Grind using a carbide burr, wire brush, and re weld…
- On some Aluminum castings , it helps to pulse using the foot pedal . Melt, add a drop of rod, and let off and let cool for a moment.
- 4047 filler rod helps too. I did not have any at the shop on the day I welded this small aluminum part, but 4047 has about 12% silicon content and that causes it to melt at a lower temperature.
4047 filler rod wets out really well…In fact, technically, its referred to a a brazing rod. It melts at a slightly lower temp and therefore there is less melting of the base metal.
Kind of the same concept as when welding cast iron parts. You dont really want to penetrate deeply because bad things happen.
I started out with an electrode that was a little too big and it causes lots of pitting. So I filed all that mess down to clean metal and swapped over to a small water cooled torch and small electrode sharpened to a point. Then I adjusted the AC balance down as low as 50% and so the pointed electrode balled up but still worked ok at low amperage. I needed that extra cleaning action from the arc to make the puddle as clean as possible.
Hopefully, I will get a photo of the finished part when it is machined back to dimension. I am curious as to how much porosity shows.
( And as always, feel free to visit us at our sister site, WeldingTipsAndTricks.com. )
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March 2, 2015 at 8:49 PM
Just when I think I’ve gone back in time and seen every single one of your videos, I stumble on this one day before yesterday. Never had a cast aluminum job slide into the shop out back, but guess what happened today…yup. Exactly what you said would happen…happened. It was a favor for a friend, a side view mirror bracket for his son’s car. I also have the HTP 221 and set it up just like you showed. Of course my job wasn’t flat and horizontal, more like hemispherical and I had to stick the tungsten out over an inch at one point. It wasn’t pretty, but it seems to be solid enough to give it a go. Thanks to you, Jody, I was able to help a friend in need. You are the welding ninja Jedi master.
February 8, 2012 at 10:43 PM
I would like to thank you for your advise. I have welded for a machine tool co,with the help of two pipe welders. having someone explane what is going on,is worthwhile,and helpful. thank you again Phillip.
February 6, 2012 at 8:52 PM
Another informative video. I can’t thank Jody enough for this line of videos and tips – he’s a one man welding school. I was about ready to sell my miller dynasty and go stupid and just do mig, but thanks to Jody am getting better every day. Love the Tig finger too! Bill
February 4, 2012 at 11:56 AM
We have a small fab shop working entirely with stainless steels, 5xxx aluminum and grade 1 & 2 titanium. Your videos are the best things to have happened to us in the past 12 years we’ve been in business. Thank you for a “reality TV” that is worth every minute. We also have your Tig Fingers and CD’s.
Respectfully,
Christopher
p.s. There are engineers out there who truly appreciate the real artists, like you guys, who make the designs and concepts come to life and make this a great country to live in; and I “R” one of them…
February 3, 2012 at 7:47 PM
WOW that is a good video. I have learned a lot from watching your videos.
If you were frustrated with the job; I would have probably pounded the part into dust.
Clay
February 3, 2012 at 1:19 PM
What a great video, very informative & to show it like it is is to cool! Been welding myself a few years(35)now and My Dad would always tell me “If it is not worth cleaning it is not worth welding.” Anyways I would like to add one little thing when welding cast alum. You will get some impurities/contamination come to the top during welding, sometimes I will stop and clean the weld & then start welding again, just makes it a little easier sometimes. Keep up the good work & have a great weekend.
The Jodster.
February 3, 2012 at 5:09 AM
Were you using straight argon or the helium mix? Video was great. Thanks
February 2, 2012 at 10:55 PM
Although I can say that this is not chalked with your prettier welds I can say you are a show it like it is kind of guy. It was ugly, but informative. I appreciate you showing us some of the uglier side if the business..
February 2, 2012 at 9:03 PM
Muy Bueno el video, se puede aprender mucho, gracias por
todo, eres el mas grande en la web, el mejor de todos
Muchas gracias por tu generosidad.
Atentamente.
Ronald Morrison
February 2, 2012 at 5:27 PM
Being a real green welder and just starting out learning TIG You are great and I would have reduced that to a black melted lump in about 10 sec. You showing us the real world and I was thinking Epoxy myself was how I would have fix it. I love the Tig Finger and been using mine to use the arc Rod as a rest but if I stick a rod it my backup to being safer by making sure I don’t burn a hand. I think I will order a 3 pack when I start my next class where they are teaching out of positions welding. Thanks for the great video’s as I know they eat a lot of time. Gene