Welding a Big Gap in Aluminum

4 Comments

1. john welding

   August 18, 2020 at 9:25 AM

   Great video, you have greatly highlighted all the points related to aluminum welding. I was highly confused about this kind of welding.

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2. John Septien

   December 28, 2013 at 4:26 PM

   Would it have been possible to use a small piece of aluminum bar stock (round or square) to take up most of the gap and then filler rod to complete the weld? This would then reduce the amount of filler rod used and reduce the cost of the repair both in time and material. (Less time between cooling periods with the amount of heat input to the weld zone).

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3. TamJeff

   November 19, 2013 at 1:09 PM

   I should also add that, in most cases of aluminum fabrication, even where one could find themselves welding up to 100 linear feet of weld per day, there really is no need for the longer pencil cap. The only real advantage to the longer cap is perhaps that it uses tungsten a little more evenly without any odd pieces left over, or if someone happens to be contaminating/grinding tungsten a lot. This is at least true where one is using balled, pure tungsten.

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4. TamJeff

   November 19, 2013 at 12:59 PM

   Good choice of procedure for a video. This is a great tactic for cast aluminum as well, that will often have pieces missing. Being able to weld build up before closing, saves from excessive shrinkage and cracking. Especially being that most cast parts will likely have a bolt pattern that needs to stay true.

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