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welding aluminum

H

Hugh

Joined
May 6, 2004
Messages
666
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155
Location
Sonoma, CA
Hi there Everyone,
I know this does not sound like a woodturning question. But humor me please. I am trying to make up a jig for woodturning and thought about making it out of aluminum......but think I may have to weld parts together. Therefore the question. What do I need to weld aluminum? Is it difficult? I have a torch and I have a buzz box electric welder - will I be able to do it with either of those welders? I know I get too many projects going but this one is working its way around my brain right now. Someone out there knows much more about this than I do. Thanks for the metal question on the woodturning forum.
Hugh
 
OK I'm no expert here. Aluminum can be welded. Not with what you have. I bought one of those aluminum repair kits you see advertised on TV. It's more of an aluminum solder but is surprisingly strong. If you make a decent mechanical joint and then join these together it's very strong. If you bond 2 pieces together in a but joint it's pretty good but I'm sure not anywhere near what a weld would be.
I don't know where to get the stuff but could go out to the shop and see if I have the instructions with it. It will have an address I'm sure.
 
I found this doing a simple google search for simple aluminum repair and weldinhttp://www.aluminumrepair.com/
 
TIG weldeing is the most versatile welding methrod for Aluminum.
Your buzz box may be able to produce a fair weld, but it would need to be used by a skilled welder with a AC welding rod.
TIG is the best way to go, but should still be done by a skilled welder. Even more so if the jig you want to make is going to be spun on a lathe.
You might want to look for a local weld shop to do this for you.

Nigel
 
Thanks for the answers Everyone. I am going to have to look into having it done for me as my welding experience is minimal. I can make two pieces of steel stick together and hold .....but it isn't pretty. I still have not worked this all out yet. Thanks for the advise though it has been helpful in my decision. That is what I love about this forum.
Hugh😀😀😀
 
Have you considered mechanical connections instead? Such as Pop rivets? For jigs in particular, the heat of welding will introduce distortions and/or locked-in stress that could make the jig less precise than needed. If there's enough contact area between the components, an epoxy, such as J-B Weld, might be another alternative.
 
Joe Greiner said:
Have you considered mechanical connections instead? Such as Pop rivets? For jigs in particular, the heat of welding will introduce distortions and/or locked-in stress that could make the jig less precise than needed. If there's enough contact area between the components, an epoxy, such as J-B Weld, might be another alternative.
Click to expand...

That is my thought also. Welding where precision alignment is needed should only be done if you plan to heat treat and machine the part after welding. Welding aluminum is a real art and not for the beginner.

I am fortunate to live in an area where there are a large number of welding businesses that do aerospace subcontract work and their work is flawless. I had some welding done on an aircraft fuel tank once and the weld was so smooth and clean that it could not even be seen except under very close inspection. One of the welders there showed off by welding several soft drink cans end-to-end. The aluminum in those cans is only a few thousandths of an inch thick and it was amazing to see that he did it without blowing a hole in the aluminum.
 
There is an art to welding aluminum but you can learn that in about 5 minutes with a couple pieces of scrap. It's not rocket science, just welding.
 
There is an art to welding aluminum but you can learn that in about 5 minutes with a couple pieces of scrap. It's not rocket science, just welding.
Click to expand...


This depends on what your welding and you have to weld with. For simple welding this stuff is the best and not to cheap but very effective and quite easy. http://www.aluminumrepair.com/

With this you can weld a hole in the bottom of a coke can which .6mm thick or around .023" Stcick with this and use Mapp gas and it wont be a problem.

Most other similar coated rods are not much good, this then leaves TIG and its not for the fainted hearted and will take way longer than 5mins
 
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