Tig welding aluminum 6061

[Charley Davidson]

I have a project at my new job that is a big billet block of 6061, it's 2 halves that get bolted together then welded to keep anyone from reverse engineering the part. I have a Syncrowave 350 LX at my disposal for the job. I have never tigged aluminum but have about 5 or 6 days to practice and get up to speed, if I don't feel I can pull it off I'll have a friend do it but would like to do it myself. It will earn me a little more respect at my job with the higher ups. I have plenty of big billet scrap to practice with.

The parts are machined mating surfaces so will be a perfect fit, can they be fusion welded or do I need to use filler rod? Please give me as much info as you can on this that will get me rolling.

[Bluesman]

Sounds like fun friend! And congrats on the new job too. Aluminum still makes me curse.

[Gadget]

Even though it sounds like a perfect butt weld I would add filler. Less likely to be able to cut it apart for reverse engineering in my opinion. Make sure everything is clean clean clean, aluminum doesn't like any contamination. As for settings I'm probably not the one to offer advice, my aluminum welding only looks good on occasion. Good luck with it though Charley, it sounds like fun.

[INSANITY]

Sounds like a sweet gig Charley. Sorry I can't offer any advice though, I'm still TIG-less. : (

[gilly]

I'm no pro either Charley.I can weld aluminum,but i don't know enough to give you the best info but,it depends on how thick the aluminum is if you are using the panel amperage.If you are using the foot pedal,i would turn the machine pretty much wide open,and i would add 5356 filler,but you might just as well wait for Stan,or one of the more experienced guys on here that does it all the time and can give you the exact method.

[Charley Davidson]

The part is about (assembled) 15"X10"X 8" The welder is equipped with all the bells and whistles. They have been trying to get me to take it to my shop for the past month and start practicing but my shop is full to the gills and I'm moving out of it soon because of an ignorant neighbor that rents from the same LL.

[Gadget]

That's gonna take some extreme amperage to do well Charley. You're going to be welding on a huge heat sink.

[Bluesman]

Stan is likely gonna tell you to preheat that sucker for sure. I would love to see a video of this but understand that may not be possible since the whole premise behind this is to prevent reverse engineering and leaking of company secrets. So, if you can't video it we will understand.

[Charley Davidson]

That's gonna take some extreme amperage to do well Charley. You're going to be welding on a huge heat sink.

Got 350 amps at my fingertips hope it's enough.

[gilly]

You might need to use a argon/helium mix with that.I will be curious to hear what the pro's advise is because i always learn something new when these threads come up.