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Aluminium stick welding difficulties!

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  • Aluminium stick welding difficulties!

    I am having lots of difficulties trying to do aluminium stick welding. I also phoned the manufacturer of the rods but they couldn't give me much information. I read in a book that I need DC and it is difficult to maintain the arc, however I am not convinced that I am doing everything right. To be honest what I need is a short video clip to see what can be achieved, and I will be very happy if someone could kindly upload one.

    Thanks
    Regards

    Marcelo

  • #2
    If you are looking to use stick as an option vs tig or mig then your going to have the troubles your encountering. Stick should be the last option, more kind of like in case of emergency type of option as tig and mig are definitely better.

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    • #3
      What are you trying to weld? Alum rods are OK for castings but they do leave a lot to be desired. You almost have to make big tacks and then chip everything off and fill in between the tacks. If you try to run a bead it may just melt and drop to the floor with no warning. I used it years ago with that method...Bob
      Bob Wright

      Spool Gun conversion. How To Do It. Below.
      http://www.millerwelds.com/resources...php?albumid=48

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      • #4
        Welding Ali with stick is problematic even on a good day. Like the others have suggested, use Mig with a spool gun or tig and call it good. The stick result seemed like it was always too brittle when I finally got enough build up to grind down to size and fit. Seems like the "miracle" sticks and stuff like that are making another upswing, but there is no replacement for seat time and experience. Even the highly experienced guys do not use the "miracle rods" since they are a waste of time and money.
        Bob
        Last edited by Rbeckett; 06-25-2011, 05:39 AM. Reason: Spelling.

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        • #5
          i recently repaired a rim from an audi, a crack 2.5" long right through the meaty area by the bead. i ground out a v close to 1/2" deep, the alu rod worked ok,i dont have a tig, so i should say that it worked great. the trick with this rod is to make sure the rod is fresh, moisture is really bad, once you strike an arc move twice as fast as stick welding steel, and keep a short arc, what are you welding and what size rod

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          • #6
            Thanks for the answers, I just tried to weld over a piece of sheet AL I found in the workshop, no idea what type is it.

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            • #7
              I forgot to ask if an inverter may be a better option to try AL stick welding, rather than just a rectifier ?

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              • #8
                Basically, what everyone is saying to you is that running AL stick is a rather expensive last ditch effort to repair something.

                Its a nightmare to run, as to have to weld extra fast, and you'll go through lots of rod.

                It won't matter if you have an inverter, transformer or hybrid

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                • #9
                  Kevin,

                  Are you saying you repaired an aluminum Audi rim with a stick welder?

                  If so, I hope you're REAL GOOD FRIENDS with your insurance agent.

                  It's one thing to do something stupid, but to later brag about it, takes the cake.
                  Syncrowave 250 DX Tigrunner
                  Dynasty 200 DX
                  Miller XMT 304 w/714D Feeder & Optima Control
                  Miller MM 251 w/Q300 & 30A SG
                  Hobart HH187
                  Dialarc 250 AC/DC
                  Hypertherm PM 600 & 1250
                  Wilton 7"x12" bandsaw
                  PC Dry Cut Saw, Dewalt Chop Saw
                  Milwaukee 8" Metal Cut Saw, Milwaukee Portaband.
                  Thermco and Smith (2) Gas Mixers
                  More grinders than hands

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                  • #10
                    well said Sundown !

                    Comment


                    • #11
                      Originally posted by lw3eov View Post
                      I am having lots of difficulties trying to do aluminium stick welding.

                      Oh, I know that pain! That is why I bought a Syncrowave 350 and it fixed that problem real quick.

                      Comment


                      • #12
                        gee sundown so nice to hear from you, always so friendly and so informed, the only thing that i do that leads to stupidity is listen to you, was i bragging or mayby just explaining the type of work that can be done with this rod, i would like to know why you are so insulting to the members on this forum, you must make alot of friends by starting up a conversation with stupid in the first sentence, lighten up dude, life is too short for attitudes

                        Comment


                        • #13
                          Kevin,

                          Would the words "not smart at all" have been more appealing to you?

                          In your own words, you mentioned Audi, which most consider to be in the "high performance" car category. Then you state, "a crack 2.5" long RIGHT THROUGH THE MEATY AREA BY THE BEAD". The solution was to "ground out a V" and fill with aluminum rod.

                          By your description, you did nothing to prevent the promulgation or spreading of the crack further. You simply "filled the void" with an inferior process.

                          I put aluminum wheel repair in the same category (regarding safety) as constructing trailers that travel over the roads. Best left to people who know what they're doing and have the "proper equipment" to do the repair in a safe manner.

                          Many posters on this board lack the experience to fully understand their own limitations. They take what others say to heart. To me, it's irresponsible to make such a suggestion that all a guy has to do is grab an aluminum stick rod and "weld up the cracks in his aluminum wheels". I do not know of any "professional" who would recommend this course of action.

                          While the aluminum stick rods may have a place for the hobbiest who's trying to "stick two pieces of metal together", they have no place when it comes to doing structural repairs on critical over the road equipment.

                          Oh, and just for the record, "making friends" is not why I come to this forum. I try to pass on many years of experience so that some of our new guys don't make the same mistakes I made over the years.
                          Syncrowave 250 DX Tigrunner
                          Dynasty 200 DX
                          Miller XMT 304 w/714D Feeder & Optima Control
                          Miller MM 251 w/Q300 & 30A SG
                          Hobart HH187
                          Dialarc 250 AC/DC
                          Hypertherm PM 600 & 1250
                          Wilton 7"x12" bandsaw
                          PC Dry Cut Saw, Dewalt Chop Saw
                          Milwaukee 8" Metal Cut Saw, Milwaukee Portaband.
                          Thermco and Smith (2) Gas Mixers
                          More grinders than hands

                          Comment


                          • #14
                            Hang in there Sundown!

                            People hate to hear that they did unwisely. Was that rim NDI'ed after welding? I doubt it.

                            Al stick rod is for tacking lightly stressed junk back together.

                            You won't see it in Air Force fab shops.

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