Detailed Cast Aluminum Welding

welcome to TFS I'm not going to waste a lot of time on the intro here I have some insanely clean crispy Arc shots and ridiculous uh detailed information about welding cast aluminum you'll probably enjoy it so yeah stick around watch it see you at the end okay those of you with a Keen Eye know this camera angle it's from weld coach and if you saw the last video I saw this part Easter egg I guess whatever uh so what are we gonna do we got to get rid of this hole right here I mean it's obviously cracked up and you know not very good looking and then we got to get rid of that hole right there by request typically you could look inside of these and you can say okay yeah that's aluminum or that's magnesium usually there's a little stamp inside there or a casting that says mg usually when you don't see that that means it's aluminum but you know we're not just gonna trust it we're going to test it so we're gonna do the smelly test this is the smelly stuff white vinegar just a little dab will do you because well this stuff stinks boom okay I put in a little too much yucky you know that's worse than it being hot and muggy back here it's like 110 112 out today and the swamp coolers that guy up there that thing doesn't work very well over about 110 degrees which means the smell of this vinegar is exceptionally muggy and nasty but either way you see it floating around in there and it looks like nothing is going on right so by comparison here this piece I know is magnesium right let's see what happens when we put smelly stuff on the magnesium little dabble do you oof too much extra smelly okay see how it kind of Foams up looks like hydrogen peroxide if you will so white vinegar will Bubble Up on magnesium it will not Bubble Up on aluminum so this is a cast aluminum part and we're gonna go dump this and clean it off because damn this stinks just a little bit of water that did the trick right there uh we don't want that one we want the other one not that one either let's fix that where is it ah there it is that's a that's a bit that's for aluminum it doesn't clog up as easy I can still use this one I don't know if you guys can see this or not but I can still use this one but you gotta can't be as aggressive on it otherwise it will clog up a little bit not hard to unclog though so that ain't too bad okay so since all of this is damaged we're basically just going to cut it out here with this carbide bird tool simple let's get rid of that nice round even hole because then we'll have more meat and more thickness to weld to [Music] okay that's done but you might have noticed that the surface of this is very very rough or clean if you will it's been sandblasted and uh cleaned with I don't know what so to get any kind of impregnation of sand or anything else like that out of this we're just gonna hit it with the wire wheel try to clean it up brighten it I have a sneaky suspicion with all this trash that's flying off of here that this is going to be a real pain in the butt but we'll know once we get the welding let's see if we can get a close-up of that all of that stuff just came off of this part could be loose particles of aluminum could be sand embedded particles okay I'm set up on a student station right now forgot to lock this in that could have been really bad I know that this is going to be a disaster right off the get-go so we're just gonna set the arc shop our Arc shot up and go from there okay so the first pass that we've got to do is what we call the junk pass we're basically just going to run over the outside are the edges on it we're going to see what the casting does for me is it going to explode is it going to Bubble Up is it going to re-solidify and give me a nice clean section to weld to it'll basically tell us everything so I'm just going to lightly run the torch around the outside there's 114 amps on the prime weld I did kick the balance up to like 40 so it would help with a little bit of cleaning and my frequency is 90 Hertz where I like it my own personal frequency if you will so it might sound a little different than it normally does but let's see what this thing gives us yeah it's a little bubbly [Laughter] you know I expected a lot worse I'm not gonna lie I'll wait yeah there's quite a bit of traction here it's not terrible this is definitely not the worst casting I've ever done if you want to see the worst casting I've ever done I got a video after that check it out after this it was pretty bad and now the bubbles are really starting to come through here I still hope I'm not in the way I'm having to take things out quite a bit here you know they're starting to come out well ain't terrible I think this one I'm just gonna fill it in with filler I don't know if I'm gonna cut a slug for it this one's probably gonna get a slug for sure that's gonna take a long time to fill up I got a feeling this one's going to be pretty nasty but hey I thought the first one was too so we'll just see [Laughter] maybe we'll actually get like a a trooper I'll show you how to whoa that section got then maybe I should pay attention while I'm doing this you think so I'll tell you I'll show you how to slug one and I'll I'll do a fill on the other one because I got a pretty good idea this would be this would be a nice learning piece here so this isn't too bad that this lower section here this is going to bite me right here I think I'll expand it a little bit too a lot of this power control you can hear the fluctuation of how much power I give it is all in my foot pedal so if I need to burn more I'll step on the pedal more if I need to burn less I'll let off the pedal kind of like keeping uh keeping up with traffic you're not smashing on the gas and you're not smashing on the brake and if you are one of those people poof make sure I'm not riding with you I'll get motion sick like crazy you know what this isn't too bad so I'm gonna plug the other side first and then we'll slug this side and then yeah you get it you get a two for here got ought to work so I'm not a billion percent sure right now how good of a shot this is coming down but I know that the arc shot's probably going to be good and I'm sure that's what you guys really want to see got two varieties here or I got two different sizes of filler one is uh this one is three Thirty second if I feel like I can't run it without it getting too clumpy I'll I'll use some 1 16. so what I really want to do is burn around this Edge and then just slowly fill it in fill it in fill it in fill it in and then we'll flip it over and then I'll burn in the other side to smooth it out well maybe I'll start with the 1 16. just to be safe well these are just little small dabs just to see how how it will like to sit in there if it'll sit in nice and smooth without bubbling out too bad on me and I know I'm doing good and I could probably after that jump up to the three thirty seconds filler I'm going to hit it a little heavy which is uh basically a fancy way of saying a lot of amps that way it'll kind of flood I don't really want like dime stacks on this thing or whatever I mean flooded out somewhat Blended and add on a it'll work a little bit better so a couple of these spots are bubbling up on me I'm just chasing it out being patient and as soon as the filler takes to it and this section right here as soon as the floor takes without bubbling out on me and that means I'm usually doing good I'm pretty much set so just working my way around this hole little by little I'm pushing quite a bit of filler in there and I'm going to be careful not to burn my gloves with any luck this uh this shot up here you can see how much I've already closed it up that's a good thing so we're gonna go in with a 332nd filler now because I'll be able to get a really heavy amount of fill inside of there because I was I was kind of chasing it out with this and it worked but I need to get a I need to get pretty heavy in there and fill it all up so let's try the 3 32nd if it works good if it doesn't work well we'll go back to the 16th and take our time because I'm putting it in here it's kind of solidifying on me pretty quick like freezing up getting kind of clumpy it doesn't have a lot of fluidity we might have to switch back I don't know I'm basically getting a little bit inside of there and then hammering down on that foot pedal see how it's blending now yeah this would be good this will do good also checking for bubbles wow I hope my head wasn't in the way and around this about here oh there's a bubble heavy on the pedals kind of smooth it out a little bit and then coming off my foot pedal as I'm swirling around here and we're full not too bad check the inside so I'm gonna flood this out I don't think I'm gonna be able to get an arc shot on that one unfortunately there's just no space for me to work pretty sure this camera went out of focus too I think I can attack it from this angle definitely no Arc shot there is no space for one in here good this I could just kind of describe it I'm hitting it heavy with the amps and letting it flow and flood in obviously seeing if I can get any bubbles out there's no real bubbles on the area where the filler was at just because it's not cast I mean it technically is now but as long as we got no bubbles we're good and this is flooding in beautifully so we are completely sealed and dang it it's getting hot inside of this thing yeah brand new pink gloves and they're starting to get all shrunken up and dirty you know maybe that's the secret here pretty gloves make pretty welds okay give it a second to cool down while I went and had some lunch this hole is about 1.2 1.3 it's about 30 mil somewhere in there I think of course it won't show ah 30 31 mil somewhere in there I got an idea okay we could happily go over and uh just cut one of these out on the fast cut here so the exact size or we could use a hole saw we could use all kinds of stuff but if we look down into here probably one of these well that's definitely too big that's steel oh wait a minute wait a minute wait a minute yeah that's pretty damn close right there of course it'll require some cleanup that ain't no big deal yeah we'll clean it up we'll Chase it out we'll weld it in get much easier than that [Laughter] tada 'll do okay this slug is in no big deal the thing to remember here is that we're not really going to use it just to weld around we could if we wanted to but I'm trying to think of the finish on this at the end of the day so what I'm going to use is just a simple backer so that way we can easily fill this thing up flood it out just in case the customer wants to like grind it smooth shape it whatever the case is there'll be plenty of metal in there so this is just kind of like a make it a little bit easier for us to run with so first pass all the way around I'm going to weld it in and then I'm going to basically just do a bunch of stacks dimes whatever back and forth just to kind of give it the whole shape of the box and then we'll flip it over and then fill the other side in I'll start with 1 16. it's probably gonna be some trash in here but can't do much about it a lot of the focus of my arc is on the cast part itself I'm just kind of letting the uh filler just bleed over [Applause] normally I'd be talking a little bit more of it this is requiring a bit more of my concentration around here so I gotta I'm gonna take a touch and control that don't worry about that little hole we'll go back and fill that up there's some of this trash out of here so to control this all in the foot pedal more power less power let it flood let it build let it do its thing there we go and move down to the bottom here this is going to be a tricky bit again most of my focus is all on the cast portion but it too is very very thin like the slug so it takes a bit of my concentration here boy oh boy it is hot in here so humid out today too but I'll do this stuff in the desert yeah I'm gonna go back around again to make sure I don't have any bubbles I'm Gonna Be Ready with the filler just in case we do But ultimately at the end of the day I want to make sure that all of this metal that's what we're putting on here is going to be higher than the original surface and that's so we can uh take it back down or grind it flush or whatever he wants in between so quite a bit of build up here [Music] I'm sticking with the 16th inch even though it's it's consuming a lot of it and that's mostly because I can control my deposition rate but it's I can give it more I can give it less I can throw it in however I need so at this point it's welding just like any other regular aluminum I can pretty much just talk I'm good to go those of you with a Keen Eye I know that I'm welding backwards right now usually we weld in the direction of our filler so I'm doing just the opposite where I round in circles here when I welded circles it's not as clean looking but it's nice to not have to stop and go back around again there we go nice little flower looking bit yep I think the center section needs a little bit more love it looks a little low [Applause] [Music] yep that'll work there's the one two three block helps with the heat too yeah do the old Switcheroo on the camera angles here just in case I don't get the arc shot you can see how uh kind of crazy this is going to be for me I don't know Flex the crap out of this torch maybe I can get in there who knows [Applause] okay we're gonna do the junk pass all right putting each other there let me go back up to the top here once again this takes a lot of my concentration so I'm not talking a whole lot here but I am thinking what if this Arc shot works I just don't know until we look at it afterwards [Music] all right I got it now that was tough uh since I'm here I'm gonna Pat this in well it doesn't really need it but we'll do it just in case I mean it certainly isn't hurting anything to have a little bit more throw it in there so this is a 332nd filler we'll just weld in some circles flooded in here I have to twist the torch around that's all all in the fingers this little manipulation of it yes my hand is super shaky this part is hot and my arm is floating so it makes their pretty uncomfortable position now I'm gonna flood go around it and blend there we go my fingers are on fire the glove is shrinking crap all right yeah brand new gloves all right I'm gonna cool off let this part cool off I am drenched and sweat right now so yeah give me a few minutes okay I messaged the customer and I asked him what do you want to do about this you know do you want me to shave it off of there blend it sculpt it whatever the case is make all that disappear and I haven't heard a response back yet so um I gotta leave it for right now unfortunately I can't cover that in this video and uh since it's hot as balls back here I don't want to sit here and wait too much longer I'm going to kill the video off here but there is what we're looking at okay pretty simple um I don't have a price tag yet but generally speaking um this work right here is roughly an hour and a half that'd be 150 bucks to fill this up and plug two holes not too bad at all if I blended this in it'd probably be another half hour or so of work maybe like 200 bucks to do this part it's not bad not bad at all I dig it so if uh you enjoyed it thanks for watching

Channel: The Fabrication Series

Views: 94,192

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Id: XTxMrkRNzJo

Length: 22min 26sec (1346 seconds)

Published: Fri Jul 21 2023