welding cast aluminium

[john057]

is there much involved in welding cast aluminum to aluminum? i want to cut a standard cast aluminum inlet manifold and weld on a inlet plenum like the picture below.

 

[Chris Stevens]

Not difficult to weld, but unless the manifold is quite thick material you might get problems with distortion.

 

[Richard.]

Generally it doesn't weld as nice as aluminium but in most cases very weldable. I don't think you'll have too many issues distortion wise as it does dissipate heat well throughout and easier to pull back into shape than ferritic metals. A little pre heat helps with cast Alu welding. Don't localise it mind if you cannot warm the whole part evenly and at a low temp then don't bother doing it.

 

[mark williams]

What's the inlet manifold off?

 

[Brad93]

Put the manifold in the oven at about 100 degrees, if its a used manifold that will help cook any grease and oil out too/which can then be removed with acetone and a rag. File any edges to be welded too don't sand or linish (thanks Richard for that tip).
Depending on how dirty the cast is you may need to use more EP+ /cleaning and a little bit more gas always helps things flow a bit better.