Needed: simple aluminum welding

[AOW162435]

I have a couple of old aluminum control arms that I would like to repurpose as shelf brackets. The arms have some small cracks (~2") that I would like to weld for cosmetic purposes (I will grind/smooth the welds as needed).
Please let me know if you do aluminum TIG welding, and if I can bring these pieces to you.


Andreas

 

[4g64loser]

I suspect that these parts are cast aluminum and thus the welds if done with GTAW may not be what you expect. I've GTAW welded up cast aluminum intake manifolds once or twice and the results are functional but less than attractive compared to welding intercooler pipe or similar non cast.

You may get better results (not to mention more people equipped for the task) my asking for GMAW. You would need to use an appropriate burr or cutting tool to bring the weld to level with the parent metal but you have said you are ok with that.

 

[mpollan1]

Interesting repurpose. Can you orient the CA so that the crack is inboard and under the shelf so that it is not visible? IMO, welding will make that area stand out all the more.

 

[G O B]

There is a solder for aluminum that would do that. I no longer have the link, but it should not be too hard for you to research.

 

[Biggfoot44]

To state the obvious , Welder 516 is owner of a welding shop .

 

[AOW162435]

I suspect that these parts are cast aluminum and thus the welds if done with GTAW may not be what you expect. I've GTAW welded up cast aluminum intake manifolds once or twice and the results are functional but less than attractive compared to welding intercooler pipe or similar non cast.

You may get better results (not to mention more people equipped for the task) my asking for GMAW. You would need to use an appropriate burr or cutting tool to bring the weld to level with the parent metal but you have said you are ok with that.

Thank you for the clarification. Yes, the arms are cast aluminum. I am set up to weld GMAW (steel / MIG) at home, just not aluminum.
Yes, I'm fine with any process that will close the cracks. I will level any excess and then bead blast the arms for a uniform finish.

Interesting repurpose. Can you orient the CA so that the crack is inboard and under the shelf so that it is not visible? IMO, welding will make that area stand out all the more.

No, the cracks will be visible.

There is a solder for aluminum that would do that. I no longer have the link, but it should not be too hard for you to research.

Those magic sticks on Amazon/IG/etc.? I actually had a few of these once and simply could not achieve success, despite using MAPP at full blast for way too long.


Andreas

 

[XCheckR]

Simple. Aluminum. Welding. Three things that rarely go together in a sentence.

 

[AOW162435]

Simple. Aluminum. Welding. Three things that rarely go together in a sentence.

Good point.


Andreas

 

[KingClown]

I can weld cracks in Aluminum and But joints still cant do lap joints. I still spend alot of time practicing. With that said Alumialloy is a aluminum brazing rod that is very easy to work with and surprisingly strong. I have used it on stripped screw threads in aluminum with no issues.

 

[KingClown]

Simple. Aluminum. Welding. Three things that rarely go together in a sentence.

Its not as bad as people make it sound eithier. Just different. Stainless or Titanium on the other hand is straight out of the 7th circle of hell

 

[4g64loser]

Its not as bad as people make it sound eithier. Just different. Stainless or Titanium on the other hand is straight out of the 7th circle of hell

You must have all the game.....I stink at aluminum compared to stainless. My aluminum GTAW is acceptable but not beautiful. I weld stainless suppressor tubes and it looks robotic, no filler rod needed. Guess I need to up my skills.

 

[John from MD]

Simple. Aluminum. Welding. Three things that rarely go together in a sentence.

Very true!

 

[KingClown]

You must have all the game.....I stink at aluminum compared to stainless. My aluminum GTAW is acceptable but not beautiful. I weld stainless suppressor tubes and it looks robotic, no filler rod needed. Guess I need to up my skills.

Im not great at aluminum but I am not horrible anymore after a metric ton of practice. Stainless and titanium though well lets just say I need alot more practice. I should have mentioned Iam specifically talking about TIG.

 

[4g64loser]

Im not great at aluminum but I am not horrible anymore after a metric ton of practice. Stainless and titanium though well lets just say I need alot more practice. I should have mentioned Iam specifically talking about TIG.

Oh, I knew you meant tig (GTAW is gas tungsten arc welding). I've never welded titanium. Mostly varying grades of steel and stainless and the majority of the stainless was firearms/suppressor related working for an 07.

I like GTAW. It really pushes me to do the prep and fit work correctly.

 

[KingClown]

Oh, I knew you meant tig (GTAW is gas tungsten arc welding). I've never welded titanium. Mostly varying grades of steel and stainless and the majority of the stainless was firearms/suppressor related working for an 07.

I like GTAW. It really pushes me to do the prep and fit work correctly.

If you can do stainless you can do titanium. Just like stainless its about gas coverage and not overheating.
I know you knew what I was talking about. It was more for others that might not or dont know what GTAW means.
I haven't weld aluminum for anything useful yet. I am learning it for my older aluminum boat where welds occasionally crack so I can reenforce those areas with plates. I have found mild steel is extremely easy to tig. Probably easier than MIG even atleast to me. Aluminum was definitely a challenge. My biggest habit is having my gas flow slightly to low unless I am using a gas lense. I catch it pretty quick though.
Stainless will be up soon if you got any tips. With Aluminum atleast in my experience you gotta back way off the heat near the end and you just gotta keep it moving. I dont know if I could ever do aluminum without the foot pedal unless I am on a very large peice. I have been practicing with 2x4 coupons. I figure if I can get those down I will be able to do almost everything I want to do. I have also found tacking and lap joints atleast for me are the hardest.

 

[toppkatt]

Its not as bad as people make it sound eithier. Just different. Stainless or Titanium on the other hand is straight out of the 7th circle of hell

I'd think the 9th circle (treachery) would be a better analogy than violence (7th circle)

 

[KingClown]

I'd think the 9th circle (treachery) would be a better analogy than violence (7th circle)

I dont know the different circles. None of them sound pleasant though. Hopefully we can get Pee Pads and Knee Pads opinions soon.

 

[CrawfishStu]

I used this on some small aluminum brackets that I made to add a gusset and it worked out well.

Alumaloy

alumaloy simple welding rods solution

smile.amazon.com

I also have an aluminum spool gun on my millermatic that you are welcome to give a run.

 

[welder516]

To state the obvious , Welder 516 is owner of a welding shop .

Thank You Bigfoot44

Yeah we weld that kind of stuff daily, can mend everything but a broken heart.

 

[Vile Shadow]

I can weld cracks in Aluminum and But joints still cant do lap joints. I still spend alot of time practicing. With that said Alumialloy is a aluminum brazing rod that is very easy to work with and surprisingly strong. I have used it on stripped screw threads in aluminum with no issues.

Wouldnt brazing be better for a lap joint?