Welding cast aluminum....

[Tractor Seabee]

Back in the old days of my refrigeration career (1950+) we had an aluminum brazing type alloy. It was low temp, had its own flux and could be used on any aluminum alloy and even aluminum to copper, bronze, or brass. We carried in the truck it to repair aluminum evaporators and aluminum to copper connections which were becoming popular. It was our emergency product for such cases. Need to google that and see what comes up.

Ron

Did some looking on the internet including Amazon. There are a number of products are out there from a solder type to brazing. Rods for arc brazing as well as torch. A lot of the Chinese stuff has bad reviews. I would read the reviews on what I as planning to buy. I have no need now so did not spend a lot of time on it. Did not find the stuff I was talking about. A refrigeration supply house may be a source.

Ron

 

[Baby Grand]

If you do use one of the heat based solutions (weld, braze or solder) make sure the housing is well vented before you apply heat. If you can also purge the housing with some inert gas, then you've got your belt & suspenders on. A sealed container filled with oil is a potential IED. Weld safe.
-Jim

 

[MinnesotaDaveChalmers]

How about drill and tap for a short bolt? A little thread sealant and all done

 

[shaeff]

Never use brake clean to clean an area that will be welded.

Edit, didn’t finish reading before posting, glad someone beat me to it!

 

[jkh62]

PC7 Epoxy.........

https://www.homedepot.com/p/PC-Products-PC-7-1-2-lb-Paste-Epoxy-087770/100649631

 

[Mark @ Everlast]

TIG weld? With the size of the casting and if it was still bolted together, you would really have to turn up the heat to battle heat loss. It works best to use a torch to preheat the area but that works best disassembled. Any oil seeping through the hole also contaminates the weld and the hole may become worse. I would try JB weld first...clean it good (brake cleaner and air compressor)...force some JBW into hole by smearing with finger, then make cap.

NEVER EVER USE BRAKE CLEANER FOR CLEANING PRIOR TO WELDING, OR ON ANYTHING THAT YOU MAY HAVE TO WELD LATER IF IT DOESN'T WORK!!!! YES! I AM SHOUTING THIS. YOU CAN DIE A PAINFUL, SLOW DEATH!

Arc Welding 11: Cleaning material with brake cleaner before welding

 

[TMGT]

It isn't all break clean that contains the chemicals referred to in that article.

Rather then shout that you should never use break clean, I think it's more important to tell people to know what is in the chemicals that they are using to clean with.

The brakleen I use is just acetone with a and a possible 1% toluene content, I buy in bulk and use a refillable sprayer so the propellant is just compressed air. There are worse chemicals out there that people use to prep for welding.
I typically use straight acetone, but if I'm out I will use 1 specific brakleen in a pinch.

I refuse to buy Chlorinated or non flammable brake clean.

 

[dragoneggs]

It isn't all break clean that contains the chemicals referred to in that article.

Rather then shout that you should never use break clean, I think it's more important to tell people to know what is in the chemicals that they are using to clean with.

The brakleen I use is just acetone with a and a possible 1% toluene content, I buy in bulk and use a refillable sprayer so the propellant is just compressed air. There are worse chemicals out there that people use to prep for welding.
I typically use straight acetone, but if I'm out I will use 1 specific brakleen in a pinch.

I refuse to buy Chlorinated or non flammable brake clean.

Agreed. Depends on the chemicals in the Brake Cleaning solution. I stay away from Tetracloroethylene. I also am also a Acetone fan.

 

[shovelrider]

I agree w/ baby grand, on the point of build-up of gases and even to the point of contamination of the oil inside of said housing. The fact that what ever you do to the spot in question, is if you take a needle point bur bit, to clean the hole. Then some of the shavings will enter the housing, is this amount of debris a problem, who knows? My point is, clean w/ maybe a small bit(bur, drill, whatever)then clean w/ acetone and fill w/desired filler, if just a small spot tig is best. Because of a controlled heat and amount of filler is not that much, in order to bridge a very small hole. just saying, make any since?