Articles & Podcast Episodes

To weld cast aluminum oil pans, first remove all oil to prevent porous welds. Clean with lacquer thinner and a scotch-brite pad. Remove oxidation, as it needs extra heat to melt. When welding, use small beads and work patiently. Use Rockmount Neptune TIG wire for a strong and durable repair. Next, select the appropriate welding … Read more

To weld a cast aluminum intake manifold, first clean the surface with a stainless steel wire brush and acetone. Preheat the manifold for better results. Use MIG or TIG welding methods, with Super Alloy 5 for repairs. Prevent contaminants and adjust your welder settings for strong bonds. Preheating the manifold is essential. This minimizes warping … Read more

Welding different aluminum alloys can be difficult due to alloy composition and corrosion rates. Methods like TIG (GTAW) and MIG (GMAW) are common. Alloys such as 5052 and 6061-T6 can be welded using the right filler metal. Proper penetration is crucial to ensure strong welds and avoid unfavorable compositions. Pre-welding preparation is critical. Clean the … Read more

To attach small aluminum parts to aluminum tubing, use TIG welding with lower heat settings to prevent burn-through. Use a 1/16” tungsten and 4043 filler rod. For thinner materials, MIG welding is an option. Use 100% argon as shielding gas. Always consult reliable sources for best practices. Additionally, use a filler rod that matches the … Read more

For welding very thin aluminum, use low heat settings to prevent burn-through. A good rule is one amp of current per 0.001 inches of thickness. Be patient; focus heat on the base longer than with steel. Use TIG welding techniques and adjust settings accurately for better results. A ceramic cup can help improve usability. Control … Read more

Yes, you can weld titanium to aluminum. The TIG (Tungsten Inert Gas) method is effective for this. It’s important to know the alloy grade for the right filler material. Explosive welding is an option but is complex and expensive. Direct laser joining may cause cold cracking, which is a significant challenge to address. One effective … Read more

To weld thin wall aluminum tubing, use TIG or MIG welding. Set 1 amp for every 0.001 inches of thickness. Clean the aluminum for better bonding. Move the torch steadily and apply heat evenly. For MIG, use 100% argon as shielding gas. Troubleshooting may be needed, so practice patience for successful joints. TIG welding provides … Read more

Welding thick aluminum plates, like 1” or 1/2” thick, needs a strong welder with 180 to 250 amps for TIG or MIG welding. Preheating the aluminum helps reduce heat loss. Cleaning materials prevents hydrogen contamination, reducing porosity. Direct heat to thicker areas for better puddle control and improved usability. Maintain a steady torch angle while … Read more

The welding temperature of aluminum depends on its type and the specific welding process used. Generally, aluminum melts at temperatures ranging from 577°C to 632°C (1070°F to 1170°F). Knowing these details helps achieve effective and successful welding results. Preheating is sometimes necessary to prevent cracks. For thicker sections, temperatures around 400°F (204°C) may be useful. … Read more

For successful aluminum TIG welding, manage heat to avoid overheating. Use the right filler rod size to prevent sticking. Clean your tungsten regularly. Keep the proper arc length and adjust AC balance for best results. Explore examples and links to resources for more techniques and tips. Additionally, choose the right filler rod. ER4047 is a … Read more