I just had a weld fail on a machine that I make , The failed joint was 1" thick 6061 aluminum plate and the with a 4.5" OD 6061 1/2 wall pipe butted into it
I ran a 90 degree tack pattern 4 tacks 3/8 long and the weld is a 3 pass weld using a 4043 3/64 filler wire weld. I have pictures showing the inside of the joint
after failure and it appears that there was a huge amount of corrosion inside the weldment. I am guessing that the weldment was not properly plugged and or
flushed after anodizing. The anno process is a hard black type III mil spec finish. Can someone explain if the acid reaction is causing strength issues and describe
what is happening ?