Stick welding aluminum

[mikefromnh]

I'm thinking the OP was just stating that for a small aluminum repair, aluminum stick is a cheap good fix.

Yeah, I had always heard that it was hard to do and not really worth trying for a newbie. But I saw it mentioned in another thread here and figured I had the perfect project to try it out on.

I'm happy enough with the results. Not pretty like tig but seems solid and cant be much worse structurally then the original welds that failed.

I've got to stop reading on here though... Pulsed mig with a push/pull spool gun sounds expensive ������

 

[Oldpath05]

"I've got to stop reading on here though... Pulsed mig with a push/pull spool gun sounds expensive"

Well, it does cost a little more then I want to pay for a quick fix, then there's the extra tank of gas. 15 years ago when I did some aluminum mig welding the extra tank was $40.00, plus the rent a weekend fee, forgot how much that was.

 

[Oldpath05]

I have used them in the past.
The learning curve is straight up!
KEEP the rods in a container! If you lay the rods down they will become wet in minutes!

Glad you mention that, didn't know. The last time I use them, had a few left over, but then every time I was done stick welding I always put the rods back in an old fridge I had, it was hooked up so a 40 watt bulb was always on to keep my electrodes dry. the only rods I didn't worry about was 6011, I put them back when ever I got to it.

 

[Oldpath05]

That's no joke. I did a repair and left the remaining rods in the plastic container they came in. Next morning I had some overpriced short pieces of aluminum wire.

Good to know.

 

[yomax4]

Good to know.

A good rule of thumb for stick welding aluminum ( with Alum Stick Rods ) Pre heat to 500 degrees. Best way to do that is to turn on your acetylene only and blacken the area you will weld. Turn on O2 and start to heat that zone. When the black soot goes away, That's 500 degrees. Now. Run your stick rod at a 90 degree angle. Straight up and down. If not it will blow out all over and look like crap. You will lay a bead in hyper speed. The Alum rods burn quick so be comfortable. Worst case, Use it as a brazing rod. Aluminum stick rods make wonderful flux coated brazing rods. Just be careful because as you know, Alum goes away in a split second once it gets up to melting temp and shows no signs before that happens. It's a blast try it and have fun.

 

[Mark @ Everlast]

I've done a little. Haven't had too much of an issue, though it is a little like holding a tiger by the tale. Here's an Everlast video on how to I did a while back.
Stick Welding Aluminum with an Everlast DC inverter PowerArc 3 - YouTube

 

[sd455dan]

"I've got to stop reading on here though... Pulsed mig with a push/pull spool gun sounds expensive"

Well, it does cost a little more then I want to pay for a quick fix, then there's the extra tank of gas. 15 years ago when I did some aluminum mig welding the extra tank was $40.00, plus the rent a weekend fee, forgot how much that was.

I just bought an 83cf tank of argon and believe it was about $170 for a full tank. i exchanged it a couple weeks back and it was about $45 Now regret not going up to the 125 cu tank or even larger.
Argon sure doesn't last like running Co2 for the mig...

 

[nybirdman]

I was a pipe welder for 40+ years;the absolute most difficult welding I did was stick aluminum.I had to finish a weld another fellow got so frustrated with that he walked away.It was a aluminum breeching(large duct) under vacuum and couldn't be shut off,over head stab in,at night ,20ft. in the air out of a man-lift.Did I mention I hate welding aluminum;TIG isn't a whole lot better or easier IMHO.

 

[Oldpath05]

I just bought an 83cf tank of argon and believe it was about $170 for a full tank. i exchanged it a couple weeks back and it was about $45 Now regret not going up to the 125 cu tank or even larger.
Argon sure doesn't last like running Co2 for the mig...

The place where I get welding supplies doesn't carry 95/5 welding gas, so 15-20 years ago if I remember right, I also use argon gas for welding thin SS, with .030 SS mig wire because of the (and or problem) with 75/25 welding gas, it seam to spattery on low heat, and or burnt through to easy, and or made the weld look sugary on the back side. Anyone else tried argon on SS welding?
At work SS welding is done with 95/5 with solid SS wire, with flux core SS wire, 75/25 is used, argon for aluminum welding.

 

[Oldpath05]

I was a pipe welder for 40+ years;the absolute most difficult welding I did was stick aluminum.I had to finish a weld another fellow got so frustrated with that he walked away.It was a aluminum breeching(large duct) under vacuum and couldn't be shut off,over head stab in,at night ,20ft. in the air out of a man-lift.Did I mention I hate welding aluminum;TIG isn't a whole lot better or easier IMHO.

But it doesn't get real hard until you have to start welding with mirrors, that's where the fun begins.