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.

 

[Shield Arc]

Couple things I learned. Just before welding use a stainless steel wire brush on the weld zone. And a little preheat helps too.

 

[mikefromnh]

It's interesting you have it labeled 0.0 arc force. This was the first time I was wondering if I could have benefited from adjustable arc force.

A couple more pics
117 amps

Before and after wire brushing the flux.

 

[Shield Arc]

Personally I think a spool gun does a much better job.

 

[Oldpath05]

I'm thinking the OP was just stating that for a small aluminum repair, aluminum stick is a cheap good fix. As far as aluminum mig welding goes, everybody that can mig weld steel, can mig weld aluminum, and it does come out a lot better, but to stick weld aluminum, you have to be good at stick welding, and then it's a challenge. Then you have the cost set up for aluminum mig welding.

I've welded a small aluminum project before with 1/8 stick on 1/4" thick angle bar, worked ok I thought, the welds was strong and lasted, I think I set my DC welder on DC straight, on the stop and starts, I cut the end of the rod for a better arc re-start.

 

[5030]

Just before welding use a stainless steel wire brush on the weld zone. And a little preheat helps too..... Yep.

I keep my stainless wire brush in the consumable drawer under my Lincoln TIG machine. Always handy.Right with my TIG finger and doeskin gloves.

 

[5030]

Personally I think a spool gun does a much better job.

Been kicking around an ESAB Pulsed Mig with a push-pull gun. I demo'd one here at the shop and the weld asthetics are amazing. TIG in appearance and 3 times the speed.

 

[Shield Arc]

This was playing with the pulse when I first got my Lincoln V350-Pro welder.

 

[bikerdib]

I've done some repair work with stick before. Actually, the first time I did it I was surprised how well it worked and how strong it turned out. However, unless it is something remote in the field, my spoolgun is the go to and that's after a good brushing with my stainless steel wire brush that hangs on the wall dedicated for aluminum.

 

[Stimw]

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!

 

[bikerdib]

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!

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.