So we are working with a company that is trying to make this weld work. They have not asked for any suggestions but I thought I would leave this here for comments. I think improper fit up and uncontrolled warping are leading to some stress causing these splits and cracks. Just wanted some opinions from you all on ways to get this working. They insist that acid cleaning and NOT using a stainless wire brush is just fine and although the welds had a "sandy" texture it was ok. Again, they did not ask my opinion of what to do. They tried to change the groove dimensions as well and to no avail did it change the issue.
This is 6061-T6 Aluminum welded with 4043 Filler material, Dimensions are included in some of the photos.
http://imgur.com/a/kYUKx <---------PHOTOS
Maxwell