Stick welding aluminum

[mikefromnh]

Figured it was a good thing for a newbie to try.


Here's the broken wheelchair ramp. Probably about 20 broken or cracked welds. And the hobart 4043 stick rods that I got on amazon for $15 delivered.


It took 2 and half rods to fix the ramp. So about four bucks. Saved over $150 vs having to replace it as this ramp was beginning to be not safe.

 

[mikefromnh]

First try.

1/8" al
4043
100 amps
Dcep

View attachment 461225

Not hot enough

 

[5030]

You found out... I did too, even though I own a TIG and MIG with a spool gun, I needed to stitch something outside so I got some too, in my case some ESAB and tried the SMAW route. It was ugly for one, and two it wasn't structurally strong at all. Mine looked like bird droppings and cracked too. I wound up stuffing the trailer in the shop door and doing it right with the MIG and spool gun. lesson learned.

SMAW with alum rod might be okay for filling in a hole but thats about it.

 

[mikefromnh]

Yeah it's not ideal. But better than nothing.

 

[mikefromnh]

105 amps

Before I wire brushed the flux off. The mess to the left is the original weld

 

[Ed of all trades]

I have done some pretty decent welds on aluminum with a stick welder. You just have to follow the rod a lot faster and not be distracted. Ed

 

[mikefromnh]

Up to 110 with better results

 

[5030]

...and you most likely used a ferrous metal wire brush (which makes it even worse). Always wire brush an aluminum pre prep joint with a stainless steel wire brush no matter what process you use....

 

[mikefromnh]

Yep, guilty as charged

Not really set up with the right stuff for aluminum. But the ramp is back in service... Jumped on it a few time and no broken welds. Much more solid then it was.

 

[k0ua]

Your a better man than me. They say to make sure your stainless wire brush has never brushed anything but aluminum too.