Broken bolt removal with TIG ?

[Smallfry]

I have a seized and broken bolt (actually a setscrew) in an aluminium housing. Caused by galvanic corrosion I imagine.

I do not want to risk damaging the housing, but I do not have oxy/acetylene, and and ordinary blowlamp cannot really concentrate the heat.

There is not room to weld a nut on it with MIG, and I dont really want to add material to it, which might prevent me from unscrewing it.

So, I wondered if I could use a TIG electrode in my inverter MMA welder, to apply some heat to the bit that remains ? Obviously no gas.
I realise it might melt the bolt a bit, but in theory could it work ?

I have no experience with TIG, hence the question

 

[Rrobson]

You’ll quickly melt the electrode without gas, and likely make a bit of a mess of the fastener. Is it big enough to get with a stick rod? You could always build it up with mig a bit at a time until you can get a nut onto it. Otherwise drill it out??

 

[123hotchef]

what size is the stud? cant you just tig a length of bar made into a T to the bolt and try unscrewing

 

[premmington]

You gotta use Argon gas - you gotta be carefull - but I do this all the while on automotive stuff in the workshop.

 

[Smallfry]

what size is the stud? cant you just tig a length of bar made into a T to the bolt and try unscrewing

Don't have a TIG welder, or any Argon. Don't hant to buy them just for this .

 

[Smallfry]

You’ll quickly melt the electrode without gas, and likely make a bit of a mess of the fastener. Is it big enough to get with a stick rod? You could always build it up with mig a bit at a time until you can get a nut onto it. Otherwise drill it out??

It is the 10mm bolt. The head end has snapped off flush with the face of the housing.

The housing is threaded and there if about 10mm of thread protruding from the other side. However, the wall of the casting is parallel to the bolt, and there is not enough space to get a nut on it, which is why I do not want to add any material to it.

I could drill it, but it is awkward to get at and see properly what I am doing. Was trying to think of an alternate method.

 

[Morrisman]

Any pictures? There may be an answer springing forth, if we can see some detail.

If the bolt head has snapped off, then there must have been room for it, so if a nut could be welded on to the stump….

 

[JOEPRO]

Don't have a TIG welder, or any Argon. Don't hant to buy them just for this .

This is your answer then! MIG it. Place a washer on first, fill carefully with weld then add a nut on top and undo it. Done it may times with 100% success including in aluminium castings. Indeed the aluminium is a little more forgiving as the mild steel weld will not take to it.

 

[bricol]

Aluminium will warm up very well even with a hot air paint stripper gun - all you are looking to do is get some movement between the two, so if you warm up the aluminium and make it expand, then it can only help.