old aluminium with new aluminium while welding old welding was cracking
Your question is more of a question than a question. Exactly what are you trying to ask?? It has been 35 years sense I finished welding school and I can probably help you but I need to know more about what you are asking, but I will take a shot in the dark at it any way. To start with, it sounds like you are trying to weld cast aluminum and this process may or may not work. It is according to the alloy. But here goes a try. 1: Grind a nice V down on both parts where they need to be joined together at. Anywhere it needs a bead of weld at. 2: Set you up a jig of some sort, even if it is bricks or something so you can put the two pieces together the way they need to fit, very fast. 3: Put both pieces in the oven and turn on to 400 degrees. 4: Wait until it reaches 400 degrees and wait 15 minutes longer. 5; This is the part you need to haul tail on, OK. Get them to the jig, set them up, weld them ASAP and then get them back in the oven ASAP. 6: Turn the oven down 50 degrees, every 10 minutes until you get to warm and then after 10 minutes turn oven off and allow to finish cooling completely. Aluminum expands and contracts rapidly. When you weld cold aluminum the weld is hot and there is too much af a heat sink in the metal so it cracks as you are welding it. I took a welding test years ago where we had to weld inconeal to stainless steel and I was the first one out of fourty some people that passed the test and they were welding as good as I was. Some better, but I was letting mine cool more than they were between passes. Cast aluminum is just the opposite. Cast Iron is the same way.
You will need to bring the temperature of what ever you're working on up to a fairly high temperature. Aluminum cools quickly, and causes the fresh weld to contract and crack as it cools.
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