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  1. #1
    Join Date
    Dec 2005
    Location
    wisconsin
    Posts
    836

    Default 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!
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  2. #2
    Join Date
    Jul 2007
    Location
    Batavia, NY
    Posts
    159

    Default

    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"
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  3. #3
    Join Date
    Dec 2005
    Location
    wisconsin
    Posts
    836

    Default

    Quote 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 Images Attached Images
    "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)

  4. #4
    Join Date
    Nov 2006
    Location
    Greeneville TN,
    Posts
    91

    Default

    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.

  5. #5
    Join Date
    Jan 2007
    Location
    Delmont, PA
    Posts
    290

    Default

    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

  6. #6
    Join Date
    Mar 2007
    Location
    Vero Beach, fl.
    Posts
    761

    Default 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!

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  7. #7
    Join Date
    Aug 2007
    Location
    New Orleans, LA
    Posts
    161

    Default

    Nice looking welds. I have always used the internal flux rods. I don't even know what the correct nomenclature is for them.
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  8. #8
    Join Date
    Jan 2007
    Location
    Delmont, PA
    Posts
    290

    Default

    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

  9. #9
    Join Date
    Aug 2007
    Location
    I live in Cheraw, South Carolina
    Posts
    112

    Default

    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

  10. #10
    Join Date
    Aug 2007
    Location
    I live in Cheraw, South Carolina
    Posts
    112

    Default

    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.

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