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Thread: How to weld TALL weld beads on 1.6mm thick Aluminum Tube?

  1. Question How to weld TALL weld beads on 1.6mm thick Aluminum Tube?

    Hi welding gurus .

    I once saw a welder at a car-speed shop several years ago build weld bead on top of thin-walled aluminum intercooler pipe (~1.6mm aluminum tubing). Although, I've had success with my EverLast 225LX machine, I'm having difficulty creating a tall weld-bead around the end of this thin-walled aluminum tubing. Does anyone know how to do it without burning through the metal or penetrating too much? (The weld on the upper right is the one I was trying to make tall, but had no luck)

    Machine: EverLast 225LX
    Tungsten: 3/32 sharpened to a point (2% Lanthanated)
    Gas: 100% Argon @ ~15 cfh
    Cup: #8 weld-craft cup with Gas Lens
    Heatsink: 1/4" thick flat-bar of aluminum rests directly below the aluminum tubing


  2. #2

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    A tall bead can be achieved by using smaller filler, with less amps...50 or so. It can also be achieved by using higher AC frequency, and using pulse with a wide separation of pulse peak, and pulse base amps with an 50% setting for time on, and about 1 hertz.

  3. #3
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    Why would a tall profile be desirable? Is it a cosmetics thing?
    DaveO
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  4. #4
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    Quote Originally Posted by DaveO View Post
    Why would a tall profile be desirable? Is it a cosmetics thing?
    Since intercooler tubing was mentioned I would guess that the reason might be hose retention.
    I would agree to go to 1/16" filler and tungsten. If you are very consistent you can use your pulser, or you can also just pulse with your foot pedal. You want to add filler while you are at high amperage, pushing as much as the puddle can take, then back off the power to let it freeze, while you move forward. Then repeat. Try not to get too much heat into the part. If it gets too hot, take a break and let things cool off.
    Long arc, short arc, heliarc and in-the-dark!

  5. Default

    Quote Originally Posted by Welderooni View Post
    Hi welding gurus .

    I once saw a welder at a car-speed shop several years ago build weld bead on top of thin-walled aluminum intercooler pipe (~1.6mm aluminum tubing). Although, I've had success with my EverLast 225LX machine, I'm having difficulty creating a tall weld-bead around the end of this thin-walled aluminum tubing. Does anyone know how to do it without burning through the metal or penetrating too much? (The weld on the upper right is the one I was trying to make tall, but had no luck)

    Machine: EverLast 225LX
    Tungsten: 3/32 sharpened to a point (2% Lanthanated)
    Gas: 100% Argon @ ~15 cfh
    Cup: #8 weld-craft cup with Gas Lens
    Heatsink: 1/4" thick flat-bar of aluminum rests directly below the aluminum tubing

    I take a long piece of 20 gauge steel sheet metal 1 inch wide, roll it in a slip-roll until it is a full circle just a little bigger than the ID of the pipe. Then squeeze it into the end of the aluminum tube, this keeps the filler rod from sinking. You can build it up to 1/4 inch tall if needed to hold on intake hoses.

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