TIG Cast Aluminum Repair Advice - TIG Welding 

Notice at 6:06 the ear-to-table tack gave way... Needed a bit more tack. -Carbide Burr used in this video: amzn.to/4bGbBfC -Oscillating tool to cut welds: amzn.to/3xL6g8Z -TIG Welder used in this video: www.6061.com/primeweld.htm -All TIG welding/aluminum fabrication questions answered in detail at www.6061.com Thanks for watching

Still love that you went from text only to better info and delivery then a discovery channel documentary. Love my tig button too. Thanks

Still very happy to hear you talk!!

7:50 quick side note about the aluminum galling up in the flutes of cutters... A short soak in a lye bath will quickly eat out the aluminum buildup in the flutes of the cutter and have you back up and running with no risk of chipping or dulling the cutting edges like you can cause by trying to dig it out with a pick or other object. Just obviously take routine precautions due to dealing with Caustic Soda (i.e., Sodium hydroxide / Lye).

I like going up to a 1/8" tungsten for the real dirty stuff (so you can get a little more cleaning) and running an autogenous burnout pass. Great video man!

Thanks Aaron! Learned a ton on this one and of course, on everything else you post up!

Thank you very much for sharing your knowledge, time and the effort to produce a video for all of us to enjoy and learn!

I really enjoy your newer content! Thank you

I like to do a bit of a tig 'wash' over cast part repairs before i add filler, do it at low amps can pull out a lot of the crap in the casting then wire brush it clean then go back in with the filler weld. Cast is also very hit an miss in quality. Awesome video aswell mate 🔥👌

Good repair with some excellent tips. One thing to keep in mind is that all castings will have porosity in them pretty much regardless of the alloy. However, A356, which is the most common die casting alloy, it is a 7% Si composition alloy which reduces the amount of porosity in the casting and increases fluidity for the pour. Lesser alloys will have lower amounts of Si which will lead to greater porosity. I will point out that the porosity that I am describing is on the microscopic scale and not the macroscopic scale as seen in the weld bead.

Great video, I’ve been using those same carbide burrs for years now and they are fantastic and a great way to get down to the good clean material.

He reuploaded this video to clarify to NOT USE chlorinated brake cleaner.

Also, if you don't clean up both sides, good enough it will pull all the contamination to the front or back of your weld Considering the item you have, great welding, mate

Love your videos man. You inspire me to get better at my aluminum welding. Chlorinated brake cleaner creates phosgene gas, which turns into hydrochloric acid in your lungs. I had some years ago I let set a couple days before welding, it still off gassed & made me sick.

vibratory saw for aluminum is brilliant. well done

Such a helpful video, thank you!!

Thank you for the info!

Pro tip: If the carbide burr gets plugged with aluminum, use drain cleaner (sodium hydroxide) in warm water. Soak the carbide in, it will chemically remove the aluminum from the carbide. It will bubble as it eats away the aluminum.

Great video sir

Thanks For Sharing!

Low key switches hands on the fly.

Thank you.

Grest content as all your videos are. Only thing I noticed that bugged me was your oscilating blade was upside down.

He speaks!!!!

The video disappeared as I was watching it.. 😂 I’m glad it’s back.

just welded up a tank my buddy brought me, he used WD on his cutoff wheel when he cut the sheet to size. it was a total PITA to get those edges clean before i tacked it up and i still had some crap in the puddle. i use bar soap on my wheels/flapper to prep AL and it seems to clean off easily with rubbing alchohol during prep. :shrug:

do you ever use milling blades on an angle grinder? I was an aluminum boat builder for years and that's all we used

If you have a part that was sprayed with chlorinated brake cleaner, say it was an engine part, and you didn't know, would going over it with acetone in the normal way be sufficient to keep you safe?

Am i crazy or did i watch this video this morning already? 🤔🤔🤔

Sounds like you are changing the frequency a bit here and there? Tia

Cool video. Thank you. What about preheating?

Gases won't come out unless it's a sealed unit That is just an air pocket

👍

Just curious why brakekleen and not acetone?

I've seen some folks recommend testing cast aluminum parts before welding to make sure they are aluminum and not magnesium. I believe a bit of white vinegar on clean metal will cause magnesium to bubble but aluminum will not react. Have you encountered magnesium in your repairs or do you think this precaution is unnecessary?

What type of filler ? ER4943 ?

déjà vu

Have you had issues with trash in the puddle if the part has been sand blasted?

G U R U😊

Left handed welders are weird.👍

So strange hearing a voice 😂