Can Aluminum be Stick Welded?

[Ben Bean]

Hello from Eagle Creek Orygun. I've done multiple searchs on the subject but have found no straight forward answers.

Can 1/4" or 3/16" aluminum be stick welded with a Miller Thunderbolt AC/DC welder? I have a chance to buy one for $150. Since being laid off I can't afford much.

Last time I did any stick welding was about 20 years ago and did some TIG a few years back so I'm not skilled at it but can lay a fairly good bead on steel.

Thanks for any & all answers,

Ben

[lugweld]

Yes,

But you need the aluminum electrodes. When you get them and weld, MOOVE it on down the seam. I haven't tried it but several people I know say its like shaking water off the end of the rod.

[cmartman46]

My brother n law welded a jon boat with a Lincoln 225 AC/DC with the dc aluminum rods. It was'nt the prettiest weld I ever seen!

[Ben Bean]

Originally Posted by lugweld

Yes,

But you need the aluminum electrodes. When you get them and weld, MOOVE it on down the seam. I haven't tried it but several people I know say its like shaking water off the end of the rod.

Lugweld, thanks for the reply. So the Thunderbolt, in your opinion, able to do the job?

thanks.......b

[6010]

The more you use it, the better it looks. But I don't think you will ever get it as pretty as you could a tig weld. I have tried it and, although the weld didn't look what you would call pretty, it was strong. Weld hot and move fast - best advice I can give you.

[Oldiron2]

Take a look at this site; click their "Products", then choose the 400 series to read what they say about aluminum welding.

http://www.messerwelding.com/

[I only get through on Internet Explorer; my Mozilla is blocking it, and I can't look into why right now.]

[BlindViper]

I had to weld up a alum turbo pedestal on my truck. I bought the rods tried them out and they disappear quick. The travel speed is far greater then steel, I went to scratch start the rod and 3/4" of it disappeared. It has not leaked in over 2 years now, and man it was far from pretty

[Ben Bean]

These are great & fast replies. Thanks guys. In some searches I found the 4043 1/8th inch rods to be the suggested rod of choice.

Oldiron, thanks for the link to Messer Welding. They have a 400 rod and also say that welding aluminum is not that hard. I guess peheating is the trick. They also mention a temp indicating crayon. I assume these are redily available at a local welding parts store???

..ben

[kneedeep]

yup
i have done it a few times and as said move fast and its a dirty weld great for strength but to make water tight I had to coat with epoxy. it worked for my needs. I also found washing with solvent before helped as the aluminium is pourus and holds oils and dirt.

[hildstrom]

Yes, check out this thread with some pics. Practice, practice, practice.
http://weldingweb.com/showthread.php?t=11505

Also, here is another link:
http://www.hildstrom.com/projects/st...num/index.html

[Ben Bean]

With all this new information I'm gonna go buy that Miller Thunderbolt AC/DC welder & have some fun! Woo-Hoo

thanks guys......
ben

[Brianstick]

Yeah, you will need DC+ to stick weld aluminum.

[Coyote]

Those Al rods will work. The ones I get are recommended on DC+, and I have not tried any thing else. I was suprised at how strong they are after I welded a 400 Chev transmission cas back togather while it was still in the truck. I really doubt the weld is anywhere close to a TIG weld in quality though. My LWS will sell them by the rod for about $1.05 a piece. The first time I used them the weld looked like a bears a** sewed up with barb wire, and the last time I used them it was not much better, but it did hold.

[wb4rt]

Aluminum or not, $150 for a Thunderbolt AC/DC is a great price around here. I would buy it at that price just to do steel if I needed a welder. I don't think you can go wrong.