[TheForge] Aluminum welding

Wed Aug 12 23:47:42 EDT 2009

According to my supplier it is 6061. I was assured that the old parts
were also 6061 but who can be sure. I would use helium next time to
weld it up since I didn't know that the helium would actually increase
the heat by a few amps, but really buy it does.

John

On 8/12/09, Keziah's Forge <blacksmith at keziahsforge.com> wrote:
> There ya go.  YOu probably replaced the original part better than new:  its
> just that the original was not strong enough to begin with, or more likely
> something else has developed, worn, been changed,  over the life of the
> machine that has increased the stress at that point.
>
> Important point is this:  the failure of the initial repair was not a
> welding problem and you should not have to eat the additional repair cost.
> Before you do it again, check to see whether the geometry of the dump/lift
> mechanism has been changed, or the hydraulics replaced with more lift power,
> or whether original load ratings are being exceeded, anything like that.
> That pivot is clearly being over-stressed.  Betcha something else mechanical
> is going on
>
>
> ----- Original Message -----
> From: "John Allen" <countrymetals at gmail.com>
> To: "Blacksmithing List Sponsored by ABANA" <theforge at mailman.qth.net>
> Sent: Wednesday, August 12, 2009 10:41 PM
> Subject: Re: [TheForge] Aluminum welding
>
>
>> 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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>>
>> --
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-- 
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