im having a tough time getting my 6061 to weld to this 6063 i have. the 6061 is 1/4X2 flat stock. the 6063 is 1/8X3/4X3/4 90* angle. anyone got any tips?

 

i just keep melting the 6063 on the side. its taking a ton of heat to even get the 6061 to puddle. machine is a syncro 200

 

i would start on the 1/4 flat stock.its thicker and once you get that to pool then add filler and move onto the 1/8 angle.its gonna take At least 140 or 150 amps to get it going fairly fast.i dont know how you are setting these two pieces up to weld.are you setting the angle on to of the flat bar?if you are you will want to start on the flat bar for sure.stomp on it and get that pool going on it and add your filler.

 

thats pretty much what i ended up doing. it worked but it looks like ****.

 

its only taking a "ton of heat" because the 1/4" is double the thickness. focus more heat on the 1/4". the differances between 6061 and 6063 are insignificant when it comes to welding. 6063 has slightly lesser ultimate tensile and yield strengths. once you weld it though yield strengths go out the window dropping from roughly 39ksi to 11ksi in the HAZ... ussually within an inch of the weld.