I'm building my own intake manifold and soon need to start welding it. Most of the plate is 3xxx (whatever utility grade is, 3022?) but I also have a piece of 6061 and my chopped stock cast manifold.

What fillers for the following:
I have to weld together the 6061 and 3xxx
I also have to weld 6061 to cast.
And I don't have to make this joint but just for my own knowledge 3xxx to cast

I have 4043 and some 5356 here, wondering if i'll need something else.

Thanks.

 

4043 or 5356 is fine....

4043 for max tensile strength or 5356 for max elongation

 

for 6061 base metal:
5356 = high strength and good ductility
5654 = best colour match after anodizing
4043 = best saltwater corrosion resistance and least cracking tendency

for 3303 base metal:
4043 = high strength
1100 = good ductility, best for colour match after anodizing and saltwater corrosion resistance
4043 = least cracking tendency

 

I'm guessing the most common probems with Al. intake manifolds is cracking so i'm assuming 4043 would be my best bet for all the joints rather than going for strength with the 5356.

 

whenever someone brings me some aluminum and they dont know the alloy it gets 4043

 

Are you sure about the 1100, that is what we use for aluminum flame welding, I was using it today.

 

i mainly use 4043 but it doesnt anodize well....luckily i dont anodize much

 

i use 4043 for all my manifolds

heres some 6061 to cast using 3/32" 4043 filler..............



AMM

 

Nice. You wouldn't happen to recall your settings for that weld would you?

Looking for frequency/balance specifically.

Thanks.

 

that particular weld was done with a 7 year old sync 250 i have at my work............ i rarely mess with its settings so im really not sure but i wanna say the balance was set at 70 ish and the freq was 60 hz cause its not adjustable, and i was at ~80 amps give or take on a torch mounted amperage controler, oh and i was also manually pulsing it too.


AMM


edited............... its s sync 250 not a 350


Modified by all_motor_mike at 11:31 AM 11/26/2007

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by all_motor_mike &raquo;</TD></TR><TR><TD CLASS="quote">i use 4043 for all my manifolds

heres some 6061 to cast using 3/32" 4043 filler..............



AMM</TD></TR></TABLE>

clean

 

I use 5356 for virtually everything.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by dave@passenger &raquo;</TD></TR><TR><TD CLASS="quote">I use 5356 for virtually everything.</TD></TR></TABLE>

Same here, i don't even have any other aluminum filler here.

 

I have a small amount of 4043 here because we do some boat ladders and stuff occasionally because we aren't far from the water, it is slightly better than 5356 for corrosion, but it has a "pitted" bead, which I hate, 5356 is shiny and notably stronger.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by weiRtech &raquo;</TD></TR><TR><TD CLASS="quote">for 6061 base metal:
5356 = high strength and good ductility
5654 = best colour match after anodizing
4043 = best saltwater corrosion resistance and least cracking tendency

for 3303 base metal:
4043 = high strength
1100 = good ductility, best for colour match after anodizing and saltwater corrosion resistance
4043 = least cracking tendency
</TD></TR></TABLE>


Nice!

Have one for mild steel and stainless?