Tackling aluminium for the first time...

[JonathanH]

Well as the title says, I've had my first go at ac welding aluminium.

I've spent 2 days running beads non stop on 3mm plate, then set about weldng 1.5mm aluminium intercooler pipes as this is the main thing I'm wanting to weld. I've managed to do this with a consistent bead (no pics yet) then I tried to weld a 7mm flange to a 1.5mm pipe, least to say I made a right mess of it lol. Has anyone got any tips it techniques for this ?

Thanks

 

[Stueeee]

Did you set the current for welding the 7mm plate? Some pre heat would be useful on the flange if it is a big chunk. I would want to use a foot pedal for this kind of welding job.

 

[JonathanH]

Thanks for the reply stuee, yes ive set it to pool the flange whilst trying to form a pool it was melting away the pipe, I suspect torch angle wouldn't help this. I'm using a foot pedal also.

A pic of my pipe bead, I think more work is needed on consistency of filler dabs to keep it uniform I also think there is too much cleaning by the machine, I've tried it both ways 30% and 70% and neither way makes a difference :/

 

[hotrodder]

Thanks for the reply stuee, yes ive set it to pool the flange whilst trying to form a pool it was melting away the pipe, I suspect torch angle wouldn't help this

It would provided arc length is correct and you get in hot and quick. As said depends on the overall size (mass) of the thicker flange somewhat but ideally a couple of hundred amps even if the flange has been preheated to get a pool going on the plate before the thinner tube gets heat soaked

You're gonna find this 'kin difficult if not impossible unless you go back to flat sheet and nail the basics first. Running beads on plate is a world apart from joining things when the result has to be air tight and will be subjected to heat cycling and vibration which can quickly end with fatigue failure if the welds are cold