Quote:
Originally Posted by Dick Linn
Aluminum must be absolutely clean for successful welding. Sanding or grinding should be done with a tool dedicated to Aluminum only. Degrease with a solvent but DO NOT use anything containing a chlorinated hydrocarbon! Brush away any oxides just prior to welding using a stainless steel brush that is dedicated for use on Aluminum only.
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Quote:
Originally Posted by Katie_UPS
Never underestimate the value in Proper Surface Preparation.
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Quote:
Originally Posted by Scott L.
You must use a stainless steel brush to clean aluminum, any carbon steel brush will leave impurites.
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It cannot be over-emphasized: ANY (any!) steel dust or even molecules will cause an Aluminum weld to be weak. ONLY Stainless steel brushes may be used, and these must never be used for any other metal. Get a small angle grinder as well.
Cleanliness is difficult but essential for welding aluminum. It oxidizes in a few seconds. Weld an inch or two, stop & clean, repeat.
Welding generates a lot of heat, and your metal will crack from thermal stress if you try to weld a long bead as one might attempt in steel. An inch at a time.
Acetone makes a suitable solvent, but of course it is dangerous and flammable.
Practice, practice, practice.