I can’t weld this aluminum

[Janderso]

Have you tried welding some aluminium that you have welded in the past just to verify your gas/etc is good?

No,
I'll see if I can find something I have confidence in.

 

[Janderso]

Ah, here we go. A piece of 6061 acted as it should.
At least I know the gas is ok.

 

[Aaron_W]

You know, it took about 30 minutes to cut these pieces with my plasma cutter.
I should just start over and do it right.
Otherwise, I’m dealing with a coolant leak, oily dirty water, fun fun.

The plasma cutter didn't have a similar effect?

 

[Janderso]

The plasma cutter didn't have a similar effect?

No,
Cut like a dream. Interesting

 

[Aaron_W]

No,
Cut like a dream. Interesting

That makes me wonder if there is something going on. Maybe give it a try with a different type of filler rod?

I was just getting into aluminum welding when my class was cancelled but it was mentioned that aluminum is fussy about the filler rod used compared to other metals. It wasn't mentioned how this presented itself.

 

[Al 1]

Jeff,
Did you try tacking without filler rod?

 

[Saguaro Slim]

Did the plasma cutting leave something behind on the cut edge?
Do you have enough material left to try running a bead in the center of a piece?

 

[Janderso]

That makes me wonder if there is something going on. Maybe give it a try with a different filler rod?

I was just getting into aluminum welding when my class was cancelled but it was mentioned that aluminum is fussy about the filler rod used compared to other metals. It wasn't mentioned how this presented itself.

I never got that far, when I experienced the smoke-spitting-popping and metallic taste in my nose and throat, I knew something wasn't right.
It must be the non-weldable aluminum.

I don't think you can compare the plasma cutter results to a aluminum in a liquid state. The plasma cutter just blows it out.
Check out the pic, after an aluminum file deburred it. It cut beautifully.
I'll pick up some 6061 sheet and try again.

 

[Janderso]

Did the plasma cutting leave something behind on the cut edge?
Do you have enough material left to try running a bead in the center of a piece?

I ground some off and wiped it down with acetone, same results.

 

[Janderso]

Must be made of unobtainum ---
I have written a friend who is quite into welding weird stuff asking him what it might be, will LYK. Aluminum might not be a really good choice for a coolant tank, as coolants are a bit caustic, and will corroded by it.

Whoa,
I didn't think of that. Shoot, I do have some .103"ish, sheet metal.
Maybe i'll go that route.
Thanks John.