Welding dissimilar thickness materials?

[dragoneggs]

Okay another post to get some chatter going... what are folks thoughts on welding dissimilar thickness mild steel (and aluminum if different). Just wondering about any tricks or techniques that make for an optimum weld in these situations. For instance I am making a stand for my grinder. I have a piece of 12x12x1/2in plate for the bottom and some 2in square tube 1/8in wall for the post. I plan to butt the post against the center of the plate.

So, I have 1/8in edge weld to 1/2in field. Should I just weld as I would putting two 1/8in together, or do I increase volts, wire speed, change angle of MIG gun? Appreciate your thoughts and reasons.

 

[muddstopper]

I would probably have the plate lying on the welding table and the tube standing on it, I would concentrate my weld on the thicker plate and weave into the tube to tie it together.

 

[yomax4]

I just focus the arc on the thicker part and wash the puddle over to the thinner part being careful not to blow through.

 

[Shield Arc]

I run a J pattern. Keep the long side of the J on the thicker material. Let the curl of the J bounce onto the thinner material.

 

[dragoneggs]

Yep thanks, mud and yo! My plan so far... wondering if my voltage or wire speed should be different than if I was doing 1/8 to 1/8? I think I will leave it as I normally do... rather than get cute and risk a blow out.

 

[dragoneggs]

I run a J pattern. Keep the long side of the J on the thicker material. Let the curl of the J bounce onto the thinner material.

Makes sense, I will try that motion... thanks SA.

 

[Big Barn]

Best to weld a bit at a time and allow to cool if you intend to have that 1/2" 12"x12" plate sit flat on the floor.

Or you could weld a heavy washer on the underside of each corner (of the base) if needed.

OR not sure if you intend on mounting the plate on something else..?

I welded 1/2" plate onto an angle iron base for my grinder. Photo shows the underside before welding.

 

[dragoneggs]

Best to weld a bit at a time and allow to cool if you intend to have that 1/2" 12"x12" plate sit flat on the floor.

Or you could weld a heavy washer on the underside of each corner (of the base) if needed.

I'm thinking of some hard rubber bushings mounted on some (Click Bond) adhesive bonded studs so I don't have drill in my concrete slab like I did with my compact bender. I'll post some pics if folks are interested in the bonded mounting solution.

 

[Shield Arc]

Best to weld a bit at a time and allow to cool if you intend to have that 1/2" 12"x12" plate sit flat on the floor.

Perfect opportunity to play with some heat shrinking. :thumbsup:

 

[Big Barn]

I'm thinking of some hard rubber bushings mounted on some (Click Bond) adhesive bonded studs so I don't have drill in my concrete slab like I did with my compact bender. I'll post some pics if folks are interested in the bonded mounting solution.

I like that idea as opposed to drilling. DO post the pics. That might be a good solution for a lot of applications.

 

[Big Barn]

Perfect opportunity to play with some heat shrinking. :thumbsup:

Done that quite a few times. Actually enjoyable when you're retired and have more patience.

 

[Code54]

Perfect opportunity to play with some heat shrinking. :thumbsup:

OK, you brought it up so now you have to explain it to us amateurs like myself - hows it work, sounds interesting!

 

[Code54]

I like that idea as opposed to drilling. DO post the pics. That might be a good solution for a lot of applications.

Click and Bond is awesome!!! Best way to add lights to a roll bar or places you don't want to weld or drill! GREAT product!

 

[Shield Arc]

OK, you brought it up so now you have to explain it to us amateurs like myself - hows it work, sounds interesting!

Little heat in the correct place, then a little water. Heat = metal expands. Cold water = metal retracts.

 

[Code54]

Very interesting - thank you

 

[Shield Arc]

This is a good book on heat shrinking!

 

[Tractor Seabee]

SA got me onto that book, very comprehensive and it does work. Another trick we used on piping was to place a welding rod under the center of the weld and either weld or clamp the ends. Square plate, put a washer under the center and weld or clamp down the corners.

Ron

 

[dragoneggs]

SA got me onto that book, very comprehensive and it does work.

Ron

Ron, Is it worth it for a hobbyist hack?

 

[Tractor Seabee]

Mark, its cheap at half the price as my old man used to say. Better than counting sheep and worth it if you only use one idea from it, it covers a myriad of subjects. Bought mine on Amazon. Try the washer idea of mine. Worst case you still have to shrink it.

Ron

 

[muddstopper]

A lot of times, I have used weld to pull a bent piece back in place. Making small beads and cooling works pretty good. A rosebud and a squirt bottle for flat metal. Have to be careful and not over do it. I have seen folks try the heat and cold rag trick to straighten out autobody panels. You look like a genius when it works like you want it, get carried away with the heat and you can also make a mess in a hurry.