Learning to TIG aluminum

THATS IT MAN !!! good job ... I'm in the process of setting up my TIG... its the best form iof welding. when you master it you will be the master. I have welding certs... but in ARC. Nice job.

Ron

Nice start! I haven't mastered tig yet. I've got a buddy that manages a shop with a couple full time welders I just go down there instead of trying to learn myself. Hope he never gets fired!

That is a skill I've yet to master myself. Good going Gary. It's on my to do list.

George

Man, you got some talent! I can't even imagine trying to make that thing air tight! Like George said, it's a skill.

I'm thankful, I've always been surronded by great welders, guys that can lay nickles, and I'm usally in good standings with them.

Good job!

I seem to screw around with a little of everything but I am a master of nothing.

Gary

MMMHH, I did not know you could weld AL with TIG. Gary, I have a dry lead TIG and 4% throughlatd Tungston, that works with Argon on stainless steel. You must have a high frequency...right? What gas shield ? what tip? ac-dc? how did you do that?

I got this from a welding web site but is basically what I am doing:

TIG Welding

1. Good process for thin metal � very clean process producing good looking welds.
2. Use Argon shielding for steel, stainless, and aluminum.
3. Use DC-Straight Polarity (DCEN) for steel and stainless. Use AC for aluminum.
4. Always use a push technique with the TIG torch.
5. Match the tungsten electrode size with the collet size.
6. Aluminum � use a pure tungsten, AWS Class EWP (green identifying band). Will form a balled-end in AC.
7. Steel and stainless steel � use a 2% thoriated tungsten, AWS Class EWTH-2 (red identifying band). Prepare a pointed-end for DCEN welding.

Keep in mind not all aluminum is weldable. I am using 6061, pure argon, AC and the green tungsten tips.

Gary

Gary,

I'm also just setting mine up TIG ... I was wondering if you could use the AC for all of them ??? I have all the TIG equipment but missing some small adapters.

I have to say the most vercitile welder is the MIG... then they have a Spool gun for Aluminum. I think becuase the wire is too weak to push thru.

I also need the TIG for the root pass on Heavy steel pipe. It gives a clean first pass on large Steam and Process Pipe then we cap it with the 7018 ARC.

Thanks for the info...I have been in contact with Miller they have been very helpful.

Ron

Polarity is critical for steel and aluminum. You have to swap them. My MIG will do aluminum and I tried it once. I got the right gas, swapped the conectors. I did spend a lot of time straightining out the spool. The only thing I could make with it was swiss cheese!

Gary

Here is the best tip I can give anyone trying to tig weld aluminum. Make sure you have a clean joint to weld. What I mean by clean is to wire brush off the outside oxide layer of metal. Aluminum oxide has a lot higher melting point than pure aluminum. If you have a heavy oxidation build up on the surface and try to weld it it will suddenly flow all over the place because the inside melted before the outside. If you take just a little more time in preperation, you can wind up with welds that look like you oxyaccetalened them. In other words, smooth, even and strong.

Welded up an aluminum block yesterday that was 8" wide and an inch thick. Cranked the sob up to 165amps! It was a plate that had broken. I ground a "v" where I was welding to get complete penetration. Clamped it with angle iron to keep it straight. Worked like a charm! We milled it back flat and looks like it was never broke. I never imagined at that kind of current my ears were ringin when I was done from the noise!

Hot D*M% let's weld up some intake manifolds!

Gary

Nice that you got it going....I like the 'fabricated' Intakes and valve covers. How would you start? Take an aluminum intake and cut it down to just the ports where the match the head? I can only imagine the challenges involved.

LPB, too many ideas, not enough focus really. My 434 stroker I am going to start with Demon carb. I have the chi head and adapter plate's. I was thinking of starting with the adapter plates and maybe fabricating an entire intake. I don't know. The other thing is my webers. I will switch to webers latter so I may fabricate a new intake for those. I have the Hal Pantera intake but again I am using adapter plates for the 400.

I Tig's the exhaust on the MGB and that went real well!

Gary

Gary are you gonna have to notch your rear deck to get the webbers to fit? If you are anyway, you may consider just making your own tunnel ram intake, a plenum chamber on top and two demons instead of just one. Top it off with the shelby oval air cleaner and you have a monster!!

quote:

Originally posted by comp2:
Welded up an aluminum block yesterday that was 8" wide and an inch thick. Cranked the sob up to 165amps! It was a plate that had broken. I ground a "v" where I was welding to get complete penetration. Clamped it with angle iron to keep it straight. Worked like a charm! We milled it back flat and looks like it was never broke. Gary

I was always told that you need to heat the block with a gas torch prior to attempting that kind of repair?

Jeff
6559

quote:

Originally posted by jeff6559:
I was always told that you need to heat the block with a gas torch prior to attempting that kind of repair?

You have to heat up cast iron, not aluminum.

Detom, The car used to have Webers before I bought it. The previous owner kept them for his GT40 project. The CHI intake already sit's up pretty high:

http://www.tmeyerinc.com/400stroker.html

Saturday I TIG'd a transmittion case for a HARLEY and yes it makes for a better job to preheat Aluminum. The reason is if you do not preheat the material around the weld, the material when welded, losses it strenght by as much as 40%. If you preheat you could actually strenghten the area and the weld which is usually WEAKER then the area around it.( Unlike steel where the weld is usually stronger, not aluminum. Aluminum weld is usually weeker thenm the area around it.) So if you desire strength ... preheat the area around 400 degrees. A simple propane torch very lightly.

Provocative Ron,

that is the oposite of what every welder has ever told me regarding aluminum. They've always said the weld is stronger.

See, I need to take that TIG class.

Your friend on the DTBB