Anyone arc welded aluminum?

eastexan · Aug 29, 2011

I was thinking about getting some aluminum electrodes for my stick welder, just to have around. Once in a while I'll run onto something aluminum that needs welding like a mower deck or a bracket. But I end up making an ugly looking splice and bolt it or try epoxy or something else.

The electrodes are getting harder to find since most everyone uses tig and mig to weld aluminum anymore. I think Lincoln has discontinued making them. Hobart and Esab still make them, but no one carries them around here. So if I get any, I'll probably have to order them.

The only time I have ever tried to weld aluminum was in high school with an oxy/acet. We were given some tv antenna tubes to weld and I never could get the hang of it. The tubes would suddenly collapse without showing any symptoms of being too hot.

I figure arc welding aluminum might be easier than oxy/acet, but really don't know. I figure it's still harder to weld than steel.
Have any of you had any experience with it? Thanks

guido · Aug 29, 2011

Hello eastexan,
Did use some aluminum stick rods.
Wasted my time. Poor flow and poor results.
Aliminun is not very easy to weld, Mig or tig, when it is clean. Stick welding aluminum is a
poor joke!
New rods maybe a bit better now, but that is my experience. Not worth the time of day.
Guido.

timcasbolt · Aug 29, 2011

me too. I've tried aluminum electrodes with no positive results. Once in a while I'll tig something and it works ok, but when I bought my new mig welder a few years ago, I got a spoolgun with it and my aluminum welding quality went way up. Now it's the only type of welding I'll do for aluminum.

Lanse · Aug 29, 2011

Well, I cant personally say that Ive done it, but I
people sure have... Heres a link to another
discussion, I hope it helps. Good luck

Untitled URL Link

ScottP · Aug 29, 2011

Eastexan
The reason most people have trouble stick welding aluminum is they try and weld it like its steel.

I'm sure Dave will be along soon to over explain it as usual.

Scott

LincolnIA · Aug 29, 2011

I tried welding a bracket on my horse trailer the other night. I had no luck what so ever. I tried everything I could think of but could not get it to work. If there is a trick to it I would like to know what it is.

eastexan · Aug 29, 2011

(quoted from post at 20:29:47 08/29/11)
I'm sure Dave will be along soon to over explain it as usual.
Scott

I'm sure you're right.

He'll probably tell me to just go buy a mig or tig and do it right. 8)

ScottP · Aug 29, 2011

The trick is to weld AWAY from the bead. Rod angled over the bead. With steel you pull the puddle, aluminum you push the puddle.

To weld aluminum with O/A, with a carbonizing flame lay a coat of soot where you want to weld.
Then adjust to a welding flame, when the soot just burns off it is ready to weld.

I hope this helps, I tried to keep it simple. These methods are how I was taught and they have worked for me.

I will say that some aluminum just wont weld for crap.

Scott

eastexan · Aug 29, 2011

(quoted from post at 21:14:37 08/29/11) The trick is to weld AWAY from the bead. Rod angled over the bead. [color=red:5003daeebe]With steel you pull the puddle, aluminum you push the puddle.[/color:5003daeebe]
To weld aluminum with O/A, with a carbonizing flame [color=red:5003daeebe]lay a coat of soot where you want to weld.[/color:5003daeebe]Then adjust to a welding flame, [color=red:5003daeebe]when the soot just burns off it is ready to weld[/color:5003daeebe].

I hope this helps, I tried to keep it simple. These methods are how I was taught and they have worked for me.

I will say that some aluminum just wont weld for crap.

Scott

Wow, thanks Scott. I hadn't heard those tricks before.
The soot thing is really interesting, because that was the hardest part for me was guessing at when the metal was just hot enough to weld but not overly hot as to cause sudden holes or sagging.

I'll drag out the torch one of these days and practice a llittle.

M-MAN · Aug 29, 2011

Never could get the old rods to weld worth a hoot. Tried a couple new rods & laid a couple beads the other day that came out ok. The new rods are much better than the old ones. Gentleman at the shop where I was said the rods I used needed 1/4 in stock for a decent weld. Don't know if their storage life is any better but the old ones woulden't keep long.

eastexan · Aug 30, 2011

(quoted from post at 15:46:53 08/29/11) Well, I cant personally say that Ive done it, but I
people sure have... Heres a link to another
discussion, I hope it helps. Good luck
Untitled URL Link

Thanks for the link, Lanse.
That poor guy kind of got beat up over there for showing his less than optimal welding beads. :shock:
I think it was Puddles that indicated they are a tough bunch at WeldingWeb.

I read a few other threads over there and it looks like aluminum welding of any kind takes a LOT of skill and practice.
And with my old stiff joints, I'll probably never be any good at it.
My welds will no doubt always look like bird droppings and dissected caterpillars.

mmidlam · Aug 31, 2011

I have welded a few parts and brackets with oxy/acet. I packed the bracket in sand so it couldn't drop away.

Anyone arc welded aluminum?

eastexan

Member

guido

Well-known Member

timcasbolt

Well-known Member

Lanse

Well-known Member

ScottP

Member

LincolnIA

Member

eastexan

Member

ScottP

Member

eastexan

Member

M-MAN

Well-known Member

eastexan

Member

mmidlam

Member

Similar threads