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  • Oxy-fuel aluminum welding

    Good Day All,
    Ok I know i nthe past I have pushed torch welding of aluminum quite a bit, especially for fuel tanks. Well I thought I would share some pictures of a test weld for fuel tank project, and show the advantages of the process for these applications.

    Material is 5052
    .028" thick
    5356 filler
    Oxy-Hydrogen with a .035" tip

    Notice the back side of the weld usually looks better then the top, perfect penetration, no oxidation. The weld is not very thick, but has very high density. Since torch welding my aluminum fuel tanks I have not had one single pinhole, leak, crack or failure of any kind.

    Enjoy!
    Attached Files
    "Better Metalworking Through Research"

    Miller Dynasty 300DX
    Miller Dynasty 200DX
    Miller Spectrum 375 extreme
    Miller Millermatic Passport

    Miller Spot Welder
    Motor-Guard stud welder

    Smith, Meco, Oxweld , Cronatron, Harris, Victor, National, Prest-o-weld, Prest-o-lite, Marquette, Century Aircraft, Craftsman, Goss, Uniweld, Purox, Linde, Eutectic, and Dillon welding torches from 1909 to Present. (58 total)

  • #2
    Very nice Mako...that is not easy to do. I like the first pic (edge) looks like good penetration and good tie in to the sides.

    Did you use a flux with it or not? I have always thought that you needed to use an aluminum powder flux (Oxweld Alumaflux) when o/a aluminum?
    Rich Ferguson
    Sales Technician
    Jackson Welding Supply Co.
    "Keep America Strong.....Weld It"
    www.jacksonweldingsupply.com

    Comment


    • #3
      Originally posted by jwsrep View Post
      Very nice Mako...that is not easy to do. I like the first pic (edge) looks like good penetration and good tie in to the sides.

      Did you use a flux with it or not? I have always thought that you needed to use an aluminum powder flux (Oxweld Alumaflux) when o/a aluminum?
      Yeah sorry, I forgot to mention the flux. I used Allstates Welding flux ( the old Alcoa/Linde formula ).

      Just for kicks, here is the same weld, stretched with a ball pein on a plate of aluminum to stretch the heck out of the weld, notice there are no cracks of any kind. Kinda gives you a warm fuzzy feeling when you have 30 gallons of Av-Gas sitting in front of you and your pulling 8g manuvers.
      Attached Files
      "Better Metalworking Through Research"

      Miller Dynasty 300DX
      Miller Dynasty 200DX
      Miller Spectrum 375 extreme
      Miller Millermatic Passport

      Miller Spot Welder
      Motor-Guard stud welder

      Smith, Meco, Oxweld , Cronatron, Harris, Victor, National, Prest-o-weld, Prest-o-lite, Marquette, Century Aircraft, Craftsman, Goss, Uniweld, Purox, Linde, Eutectic, and Dillon welding torches from 1909 to Present. (58 total)

      Comment


      • #4
        Great job, I have tried that a couple of times with no luck I think I was using the wrong flux. It must be a rare process when I went to the weld supply store they said they have never seen it done or couldnt tell me what flux to use. Then the tried to sell me a tig LOL.
        sigpichttp://www.sharpsiron.com

        Comment


        • #5
          Hey mako,
          That is some fine O/A AL welding. I love O/A and have been using it 43+ years and been O/A Alum. for many years. I also do MIG & TIG Alum. but always keep brushed up with O/A. You can really get the "feel" of the AL with O/A and I wish more welders would get into the multitude of welding facets that O/A can do. The ease of transition into TIG is really amazing if one does a few years of O/A prior to TIG. It's good to see those like yourself who do quality AL welding and "push" the O/A process.......BTW, I use the same flux......Thanks....Denny
          * Complete welding, machine, & fab shop *
          * Mobile unit *
          * Finally retired *
          ____________________________________________

          * A man's word is his honor..... without honor, there is nothing. *
          * Words are like bullets..... once they leave your muzzle, you cannot get them back. *
          * I have no reservation to kill nor hesitation to die for the U.S. Constitution & the American Flag. *
          * Age is a state of mind..... at my age, you cannot fathom what is in my mind. *

          Comment


          • #6
            Oxy-fuel aluminum welding

            I've done my fair share of brazing over the years but never tried O/A or O/H welding on aluminum. I would love to know more about it and any pointers, tips, or publications you could help me with would be greatly appreciated. I am getting more and more aluminum work coming into the shop and think it would be a lot quicker and more efficient to do the oxy fuel welding over mig or tig. I've asked a lot of old time welders about o/a or o/h on aluminum and have not been able to find any one that had ever done it before. We have three LWS's in the area and none of them were any help in the past when I had asked them about torch types, tips, fluxes, etc, etc...

            Once again I would really appreciate any and all info you would be willing to share. Dave



            yorkiepap, haven't seen you in a while, glad to see you post again
            If necessity is the Mother of Invention, I must be the Father of Desperation!

            sigpicJohn Blewett III 10-22-73 to 8-16-07
            Another racing great gone but not to be forgotten.http://video.google.com/videoplay?do...modified&hl=en

            Comment


            • #7
              Nice looking welds. I have always used the internal flux rods. I don't even know what the correct nomenclature is for them.
              Lincoln: Eagle 10,000, Weld-Pak HD, Weld-Pak 155, AC-225, LN-25 wirefeeder
              Miller: Syncrowave 250DX Tigrunner
              Westinghouse: 400+ amp AC
              ThermalArc Handy wirefeeder
              1 Harris, 3 Victor O/A rigs
              Arcair gouger
              Too many other power toys to list.

              Do it right, do it once. And in all things ya get what ya pay for.

              Comment


              • #8
                Hey Dave(dabar39),
                Thanks man....I kinda stayed away when all the personality conflicts started. I'm not fond of those kinds of responses on a forum, any forum, that is supposed to help, enlighten, and give inexperienced or experienced welders a place to LEARN! I read this forum every day as I do with 2 others I like and contribute to. Mako's post kinda lit me up with O/A and I really like to help others really learn what the potentials are for O/A..even if one just wants to be able to do some "home repairs/fixups" and have a process that is quite inexpensive. Sorry for getting off tangent a bit. Anyway, I hope to be able to contribute a bit more now & again.....Denny
                * Complete welding, machine, & fab shop *
                * Mobile unit *
                * Finally retired *
                ____________________________________________

                * A man's word is his honor..... without honor, there is nothing. *
                * Words are like bullets..... once they leave your muzzle, you cannot get them back. *
                * I have no reservation to kill nor hesitation to die for the U.S. Constitution & the American Flag. *
                * Age is a state of mind..... at my age, you cannot fathom what is in my mind. *

                Comment


                • #9
                  I found this site with information on rods. It may be of interest to someone.
                  They also have some videos of repair work.
                  WWW.muggyweld.com
                  sigpic 6010
                  If I had know I was going to live this long, I would have taken better care of myself.

                  Comment


                  • #10
                    Oh, almost forgot. That is a pretty weld Makoman. I mistook it for a tig weld at first. I hope one day I can make it look like that.
                    sigpic 6010
                    If I had know I was going to live this long, I would have taken better care of myself.

                    Comment


                    • #11
                      Nice welds. My dad used to gas weld everything. I wish I paid more attention to the stuff when he was still alive Unfortunately, I didn't get into it again until my mom asked me to clean out his workshop last year.

                      Comment


                      • #12
                        Wow nice welds, I too have brazed alot yrs ago. but now it seems, with a plasma cutter, TIG and MIG, I don't use the torch for much except heating things, same with stick, just sits there mostly. Like Dabar, I am interested in it so anything you've made I'd like to see. Also any info is appreciated.
                        Scott
                        HMW [Heavy Metal welding]

                        Comment


                        • #13
                          Originally posted by 6010 View Post
                          I found this site with information on rods. It may be of interest to someone.
                          They also have some videos of repair work.
                          WWW.muggyweld.com

                          I have to warn you, that stuff isnt "welding" at all, its more like a low temp braze. The cored rods are also actually brazing rod. The drawback is that the brazing is not ductile at all, and is designed to be used with surface area I.E. a lap joint. Butt welds with brazing material arent that reliable and unfortunately the entrie area has to be removed to re-do a braze as the material infects the parent metal at welding temp.

                          I use either Allstates aluminum welding flux, or the flux sold by Kent at www.tinmantech.com. He also is a good source of learning material. Use a good spring water like evian with the flux.

                          You can use pretty much any torch you want, heck ive even used a cutting torch on castings! OH and OA can both be used with great results. If anyone has any specific questions feel free to e-mail me anovak@mercmarine.com

                          -Aaron
                          "Better Metalworking Through Research"

                          Miller Dynasty 300DX
                          Miller Dynasty 200DX
                          Miller Spectrum 375 extreme
                          Miller Millermatic Passport

                          Miller Spot Welder
                          Motor-Guard stud welder

                          Smith, Meco, Oxweld , Cronatron, Harris, Victor, National, Prest-o-weld, Prest-o-lite, Marquette, Century Aircraft, Craftsman, Goss, Uniweld, Purox, Linde, Eutectic, and Dillon welding torches from 1909 to Present. (58 total)

                          Comment


                          • #14
                            Originally posted by makoman1860 View Post
                            I have to warn you, that stuff isnt "welding" at all, its more like a low temp braze. The cored rods are also actually brazing rod. The drawback is that the brazing is not ductile at all, and is designed to be used with surface area I.E. a lap joint. Butt welds with brazing material arent that reliable and unfortunately the entrie area has to be removed to re-do a braze as the material infects the parent metal at welding temp.

                            I use either Allstates aluminum welding flux, or the flux sold by Kent at www.tinmantech.com. He also is a good source of learning material. Use a good spring water like evian with the flux.

                            You can use pretty much any torch you want, heck ive even used a cutting torch on castings! OH and OA can both be used with great results. If anyone has any specific questions feel free to e-mail me anovak@mercmarine.com

                            -Aaron
                            Correct on the brazing/welding info posted above. Basically with O/A welding whether steel or aluminum you actually get the parent material to a molten state (puddle). With brazing the only thing that melts is the filler.

                            The Allstate flux you use is pretty much the same as the old Oxweld Alumaflux I believe. Oxweld was a trademark of Linde...then L-tec...then Esab. And then Esab bought Allstate. You can't tell the players without a program..

                            Aaron, again nice work...that's old school stuff bro!
                            Rich Ferguson
                            Sales Technician
                            Jackson Welding Supply Co.
                            "Keep America Strong.....Weld It"
                            www.jacksonweldingsupply.com

                            Comment

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