TIG welding cast aluminum

[Goat Driver]

Had a cast aluminum engine part, a timing chain cover, to weld up yesterday. These cast aluminum pieces are always interesting to weld on, sometimes it is good, sometimes not so good....

Syncrowave 200, 175 amps, balance 7.3, straight argon @ 17cfh, 2% Lanthanated tungsten (sharp tip), 4043 filler

damaged area

a hole worn through the casting allowing water into the engine oil

welded up

 

[Ohmthis]

I've had hit and miss times welding cast aluminum. It seems that the parts that have had oil in them are the worst (oil pans, motorcycle cases, small engines). I've had best success putting the piece on the gas grill for about 15min to burn out as much as possible before cleaning and welding. Your repair looks picture perfect.

 

[Goat Driver]

I've had hit and miss times welding cast aluminum. It seems that the parts that have had oil in them are the worst (oil pans, motorcycle cases, small engines). I've had best success putting the piece on the gas grill for about 15min to burn out as much as possible before cleaning and welding. Your repair looks picture perfect.

Thanks Ohmthis.
I have had to "pre-heat" some times too. I use a propane torch some times, and have done as you said used a grill to burn out some oil and contaminates.
It seems that companies use different "concoctions" for the cast aluminum and some will weld pretty good and some are just a real headache. I always let people know up front that attempting to weld something like this is a potential disaster, if it fails and is not weldable....I am not responsible and in the end it could require their complete replacement of the part. So is life....

 

[BigMike782]

It's the zinc level that makes or breaks welding cast aluminum. The higher the zinc the closer it gets to un weldable.

Nice looking repair

 

[motobilt]

It's the zinc level that makes or breaks welding cast aluminum. The higher the zinc the closer it gets to un weldable.

Nice looking repair

Along with the amount of trash in the aluminum.

 

[zkling]

Good job, quality repair.

 

[Goat Driver]

It's the zinc level that makes or breaks welding cast aluminum. The higher the zinc the closer it gets to un weldable.

Nice looking repair

Thanks BigMike

Along with the amount of trash in the aluminum.

Sometimes I wonder what they do put in some the cast stuff....

Good job, quality repair.

Thanks zkling

 

[LigouriRd]

That looks familiar, Nissan SR20?

 

[Goat Driver]

That looks familiar, Nissan SR20?

I believe your are correct.

 

[youngnstudly]

You did good on that repair. Cast aluminum can be such a pain to weld when the conditions are not right. I avoid it when I can, but if it's something for myself, I don't hesitate to weld it. As many others have figured out, when it's oily, dirty, or happens to be a rough sand casting that is "sandy", welding it can make you want to smash the part with a hammer and walk away.

I use a propane torch for preheating, but I also have a hot plate that works good too. I find that soaking the part overnight can make a big difference, but I've only resorted to that a few times so far. I figure if it's not clean enough for welding after a few wipe downs with acetone, the hammer trick usually saves a lot of pain, grief, and unnecessary swearing! Smash it, walk away, and move on with your life!

Andy