only thing iv ever used aluminium thicker than 3mm for is cutting letters out of...
Hotrodder welded some real tricky 1mm-wall-thickness pure ally charge cooler cores to 6mm alloy plate for me for my bike. The supplier's R&D guy said it would be 'very, very difficult' when I emailed him to ask his advice on the idea. Hotrodder made it look too easy though
Thought my ears were burning
Didn't weld the whole thing up, did the initial welding (cores to plates and tacking up the plenum) so that Pete could finish fabricating it and finished up a few bits after the casing was finish welded
200A wasn't really enough once the charge cooler was nearing completion- the cores were welded in at around 160-170A, had the welder flat out for some of the fillet welds and it was still struggling to give a proper weld puddle, even with some preheat. One of the few jobs i've done that showed it's limits