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Up Topic Welding Industry / Welding Fundamentals / Tips for cleaning cast Aluminum
- By jwright650 (*****) Date 09-09-2014 11:30
Someone had asked if we could move this thread to the Tips and Tricks part of the forum, so I created a post and merged the original thread into this one. -moderator
- - By southern_style (*) Date 09-06-2014 15:49
Got a call yesterday about welding on aluminum parts that are casted such as a part for a vehicle I have welded many different things made of aluminum but can't recall anything ever looking as if it could have been a casted part. I am curious if anyone has welded anything like this before and if so do you suggest any procedures other than what you would do for any other kind of aluminum thanks
Parent - By 522029 (***) Date 09-06-2014 17:56
Usually a lot of impurities in the castings. I have repaired many GM intake manifolds and other cast parts using 4043. I just purchased some 4943 and have only used it once so far, successfully, on cast aluminum.
No problems.

Griff
Parent - - By lo-hi (**) Date 09-06-2014 21:39
Welded bunch's of transmissions and motorcycle cases. Clean as much as possible and float the soot to the top and clean again. A good die grinder with the aluminum burrs is a  necessity, but hang on and be careful of direction of cut or you could create more work. If its a crack repair, stay away from solvents and chemicals, clean with a grinder and burr tool and the dirt will float to the puddle. Unless its something special, 4043 should be fine. Some of the front wheel drive trans parts are magnesium, but you will know that right away. good luck hope this helps.
Parent - - By southern_style (*) Date 09-06-2014 22:09
Ok thanks guys I appreciate it much
Parent - By Cumminsguy71 (*****) Date 09-07-2014 00:16
Welded a cast aluminum flag pole that broke off at the base in a tornado. Real dirty stuff to weld, it's been many years but believe I used the 4043 myself. Grind, bevel with aluminum appropriate wheels, patience.
Parent - - By 357max (***) Date 09-10-2014 03:47
FYI ~ GTAW Aluminum produces a "white" arc, Magnesium a "green" arc and Zinc Die Cast a "purple" arc. The intensity of the color is reflective of the alloy elements.
Parent - - By Lawrence (*****) Date 09-10-2014 11:52 Edited 09-10-2014 11:56
Memories !

This reminds me that I was chained to a workbench in 1989-1991 (low union seniority) and forced to repair magnesium gearboxes for DC10's, 727's and the rest of the fleet.

I learned SO MUCH !

One casting could be repaired in an hour... And another identical casting with similar repairs would take a couple of days...

Magnesium castings are capricious :)

I'm one of the old salty dogs that has the esoteric knowledge to weld Mag with DC+ and Helium  (and a tungsten as thick as your pinky)

Edit:  I don't hate the chlorinated solvents like you do...   I love them..  Just need the correct PPE and to make sure they are fully evaporated and vented before striking the arc.  

NOthing cleans a casting like trichloroethane
Parent - - By 357max (***) Date 09-11-2014 15:50
Yes trichloethane is a fantastic cleaner. OSHA reg requires a chlorinated hydrocarbon be 200 feet from a welding arc. Phosgene gas may be produced and the poisoning effects are not reversible. Be safe out there.
Parent - - By ssbn727 (*****) Date 09-11-2014 20:31
Just to add to your post 357 Max, here's an OSHA Guideline in .pdf describing Trichloroethylene as a potential human carcinogen:

http://www.cdc.gov/niosh/docs/81-123/pdfs/0629.pdf

This is an older article that briefly describes an accident in which one worker died as a result of a 40 gallon spill of Trichloroethylene and oSHA fined the company for over $100,00.00:

http://www.reliableplant.com/Read/8947/c_a-faces-$108k-osha-fine-following-fatal-accident

This is from GENERAL PROVISIONS, 29 CFR 1910.252:
"Cleaning compounds. Manufacturer's instructions and other precautions must be followed when cleaning materials are used. Degreasing and other cleaning operations involving chlorinated hydrocarbons must be so located that no vapors from these operations will reach or be drawn into the atmosphere surrounding any welding operation. In addition, trichloroethylene and perchloroethylene should be kept out of atmospheres penetrated by the ultraviolet radiation of gas-shielded welding operations."

http://safety.blr.com/analysis/hazardous-substances-and-materials/welding-cutting-and-brazing/National/

Here's some more links that cover this chemical in detail and the hazards and damage this chemical can do to your body from over exposure and how to protect yourself:

http://www.atsdr.cdc.gov/csem/csem.asp?csem=15&po=8

http://www.atsdr.cdc.gov/csem/csem.asp?csem=15&po=9

http://www.atsdr.cdc.gov/csem/csem.asp?csem=15&po=10

http://www.atsdr.cdc.gov/csem/csem.asp?csem=15&po=11

http://www.atsdr.cdc.gov/csem/csem.asp?csem=15&po=12

http://www.atsdr.cdc.gov/csem/csem.asp?csem=15&po=13

http://www.atsdr.cdc.gov/csem/csem.asp?csem=15&po=14

This document is intended primarily as a guide for non-technical users of Material Safety Data Sheets, in particular, those who use MSDSs presented in the 16-heading international format and prepared in accordance with U.S. and/or Canadian requirements... It explains the types of information found in each section of these MSDSs and how it can be used to gain an understanding of the hazards and precautions necessary for the safe use of chemical products...

http://ccinfoweb.ccohs.ca/help/msds/msdsINTGUIDE.html

Here's an actual MSDS or two for Trichloroethylene:

http://www.sfm.state.or.us/CR2K_SubDB/MSDS/TRICHLOROETHYLENE_DEGREASER.PDF

http://www.pharmcoaaper.com/pages/MSDS/MSDS_T/trichloroethylene.pdf

Be Safe is absolutely right!

Respectfully,
Henry
Parent - By 357max (***) Date 09-12-2014 03:56
MSDS is great information. I believe the name, it is being changed to MDS Material Data Sheet versus Material Safety Data Sheet. A little more inclusive possibly? Again, be safe out there
Parent - - By 357max (***) Date 09-08-2014 20:43
A good, but timely process to clean aluminum is boil it in a very large pot/barrel. The boiling temperature opens up the aluminum and allows the oil to float to the surface. Skimming and adding fresh water is needed so a film of oil does not accumulate on the surface. When no oil rises to the surface. then wipe down with acetone and then use the carbide burr. Finally before welding wipe with acetone. Brake Cleaner works but be very very very sure that it does not contain a chloride hydrocarbon. Do not use it if "...CHLOR..." is shown on the ingredients.
Parent - - By ssbn727 (*****) Date 09-09-2014 06:13
Excellent tips for cleaning cast Aluminium, or as Al affectionately calls it: "The almost metal...":lol::yell::twisted::yell::lol::wink::cool:

This post should be in the "Tricks of the Trade" section don't you think John?

Respectfully,
Henry
Parent - By jwright650 (*****) Date 09-09-2014 11:32
:wink:
Up Topic Welding Industry / Welding Fundamentals / Tips for cleaning cast Aluminum

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