Die Cast Aluminum Welding Technique and Filler?

by Tim Smith
(Enumclaw, Wa.)

What is the best process for welding die cast aluminum? What type of filler? Thank you.

Tim.

Comments for Die Cast Aluminum Welding Technique and Filler?

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Feb 21, 2016
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Depends on what you are welding.
by: Anonymous

Depends if its cast, such as patio furniture, chainsaw cases, etc.

Jan 07, 2016
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Dura Fix Aluminum welding rods
by: Mike Hancock

This is a new process all you need is a small propane torch you can get from Wal mart--You have to pre heat and melt your rod cross ways you can even fill in a 1/2" hole in the bottom of a coke can for practice once you get the hang of it do it on your part and fill in your thickness of what you want then grind and polish you can even drill and tap works great on cracked intakes on any aluminum car parts i love to show people how to weld the coke can-thanks'

Jun 07, 2015
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Aluma-weld
by: Pat A

I think that Aluma-weld is still available at Harbor Freight. The included instructions seem a little unclear, but the method is to basically (1) clean the areas to be joined (2) butter the joints with the rod (3) then heat the break and join the parts together. No flux is needed, but you could probably use aluminum jelly to remove any oxidation.

Apr 25, 2015
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What It Should Sound Like
by: Richard Parker

One thing I forgot to mention is that the tungsten I used was pure tungsten 1/8 inch. It will ball up, and your welds will be pristine. AC balance should be around 8, if your are using an older machine. A newer machine, put the settings on 75%, it should sound like bee's, set the gas higher to cool the torch, cup and tungsten on the post flow. If the welds are dirty looking afterwards, it isn't clean metal. Keep the metal clean. I use acetone it leaves no residue on the metal.

Apr 05, 2015
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Tig welder and electronic sheet metal
by: Richard parker

I have done a lot of intakes for cars, the last was for a ford mustang 302. I cleaned with thinner and wired brushed the area, gouged the area out, re-cleaned the area with thinner and then clamped it to a plate. Using the ac setup with an argon and helium mix and 1/8 " tungsten, number 8 cup, 25 pounds of gas, pre heated with the tig torch, I welded it with 4043 wire. And at the end ease off the heat and drop back on the fillet. Never cracked again! Please do not chill with water or air, if possible burry it in kitty litter to cool on its own.

Feb 24, 2015
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Tig Welding Die Cast Aluminum
by: Goldtrigger

Tig welding would be my process. Preheat the part if possible to prevent cracking. The above comments on rod are also applicable, not sure what the part is made of but would like to see the materiel to decide the welding rod.

Clean the area to be welded with acetone before welding. As stated above, it may not be possible to weld it. Cast aluminum is really tricky, sometimes it just colapses and turns to crap when heated. Good luck.

Feb 08, 2015
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die cast aluminum
by: Michael

Just an opinion but I believe I would use TIG and depending on the thickness would use multiple passes while letting it cool to the point of hand touch between passes. Use AC current and blunt the end of your tungsten. Depending on the thickness of the material would call for 1/8 or 3/32 tungsten and rod. Remember to keep it clean by grinding brushing and alcohol or acetone. Be sure to grind your stops and starts to keep your puddle clean and keep your arc length constant. Check with your local welding supply for the rod that will match the material. Keep your puddle about the same size as your filler rod will help keep it cool and draw less slag out of the cast material.
Also step welding will help keep the heat down.

Jan 26, 2015
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Welding Aluminum
by: Anonymous

Aladin Rod and Flux in Grand Rapids, Michigan use to sell 3n1 rod, Gordon Hill was the owner and he has passed. But I think you can still find the rod, he too use to weld alum. furniture together, cans and many other things, at trade shows. He use to make it in GR. E bay has some of the wounder rod like it for sale.

Aug 25, 2014
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Welding Aluminum
by: T. Marts

As J. Miller has stated, there is a welding rod available to weld cast aluminum and "pot Metal"

I saw the advertisement on TV and sent away for it. It is called "Alumi-weld".

I used it to repair a broken "ear" of a Holley Carb and also an aluminum intake manifold.

It only required a hand held propane torch.

Practice first on anything aluminum before tackling your main project.

Aug 02, 2014
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Additional Cast Aluminum Welding Tips
by: J Mills

I ave an incomplete answer previously. Tig welding is the preferred process. AC current, argon shielding gas. If thick material parts are welded, helium can be used along with the argon. Some cast material is porous so if the weld bead leaks a chipping hammer can be used to peen the bead. It works for me.

Aug 01, 2014
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Former Boeing Welder
by: Jerrell Mills

Ask a welding supplier in your area for their recommendation. Some aluminum isn't considered to be weldable. Aircraft spruce & specialty did have welding rod they sold to weld some non-weldable aluminum, ph 1-877-4-spruce. I think the product was seen at fairs demonstrating welding aluminum cans together.

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