Tips for cast aluminum (cyl. head) weld?

Date 11-09-2003 01:11

I have an aluminum cylinder head that has some badly corroded and pitted areas that I thought I might try to fill in with my TIG welding skills. Any suggestions for a filler rod to use on an aluminum casting? Any tips in general?

I have noticed that the corrosion is deeper than it looked at first and the more I grind using a pointed carbide bit, the more I see that it is very hard to reach a depth where there is clean aluminum without gray oxidized spots. I am guessing I must grind all the way to clean metal? I haven't really welded "dirty" corroded aluminum like this. Most of my projects so far have been fresh aluminum stock. I'll take any pointers you can give for this type of welding.

Thank you,
-Ken the 'tig as a hobby' guy.

By dseman

Date 11-09-2003 01:30

Hi Ken,
Check these two articles out, especially the first one with the highlighted area in blue. Hopefully, that will help you with your questions.

http://www.tomorrowstechnician.com/tt/tt80276.htm

http://www.automotiverebuilder.com/ar/ar49976.htm

-dseman

By Ken377LX (*)

Date 12-07-2003 07:24

Thanks. That is helpful.

By brande

Date 12-07-2003 07:52

Most aluminum castings are silicon based alloys.
Therefore, a 4043 or 4047 filler rod will work.
There are some 5000 series castings, but they are rare.
The silicon based alloys also seem to run better than the 5000 series.

Let us know how you make out.

Good Luck

brande