[TheForge] Aluminum welding

[John Allen]

The initial problem was where the steel pivot connects to the aluminum
dump frame. It started ripping the web horizontally. I will probably
have to replace the whole piece. The truck is about 15 years old.



On 8/12/09, Larry Brown <lp.brown at verizon.net> wrote:
>
> Option 1; Figure out why it was messed up to begin with, stress, abuse. If
> the dump action attaches there, its a lot of stress. You could change the
> whole   piece if you are getting paid. I would add supports inside the web
> (Fish plates) if possible in that area to prevent future breakage.
>
> Option 2; If you are unlucky enough to be doing this with out proper
> compensation. Figure out why it was messed up to begin with, stress, abuse.
> Cut out broken weld, re weld, Fishplate with heavy stock inside the webs
> and if there is clearance top and bottom of beam, Several feet long, I
> would try for at least 18" each side if there is clearance, more if
> possible. Cut corners of fishplates off. Only weld ends in center of beam
> just to hold down and space welds along top and bottom to anchor over
> repair. I would try not to weld the whole length but weld several inches,
> skip several, weld, etc
>
> I was shown by a tank welder that acetone helps get a good mig weld when
> used for cleaning instead of an acid.
> Warning; Acteone fumes can Go BOOM if not ventilated, so I didn't tell you
> this. Dump body has open air, just don't put the can between your feet
>
> Hope this answers your question or helps solve your problem. Figure out the
> initial problem first, it may save you time if you can see why it broke
>
> L Brown
>
>
> At 06:54 PM 8/12/2009 -0400, you wrote:
>>I welded an aluminum dump truck dump body frame rail together since a
>>4 foot section had to be replaced at the pivot end. I replaced the 6
>>inch I beam with a new one and I welded it together. The owner has
>>contacted me that the weld broke. I fixed it and gave it back. He now
>>said it did it again. It is breaking from the top of the beam down.
>>
>>I made straight cuts and there was about a 3/8 inch between the old
>>one and the new piece. I mig welded the outside after I cleaned the
>>joint with a brand new stainless steel wire wheel and then aluminum
>>cleaner, muradic acid. I welded it at proper settings and helium gas.
>>I even cross stitched weld over the vertical weld to improve strength.
>>I am using 4043 3/64 wire
>>
>>After it broke the first time, I asked other welders what I did wrong,
>>they don't know. I am loosing my mind trying to figure it what I am
>>doing wrong. I do not have a welder heavy enough to put out 250 amps
>>to tig weld it but I do have a 302 trailblazer that I could run 225
>>amps to tig it. I don't know what to do besides replacing the entire
>>beam and eliminate the weld.
>>
>>--
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