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Spot Welding Machine for cleaning Al. off exhaust tube

Spot Welding Machine for cleaning Al. off exhaust tube

Welding Automation for cleaning Al. off exhaust tube

laser Welding Machine for cleaning Al. off exhaust tube

Welding Automation for cleaning Al. off exhaust tube

Welding Automation for cleaning Al. off exhaust tube

Platform Spot Welding Machine for cleaning Al. off exhaust tube

Platform Spot Welding Machine for cleaning Al. off exhaust tube

cleaning Al. off exhaust tube


Tue, 31 Aug 2021 15:28:15 GMT
I will be welding up (cobbleing up? )  an exhaust on a small portable Gen set.The last exhaust I welded (tractor) I used a 1/16 stick and a lap weld.  I ground and sandedoff the aluminum  for about 2 inches on each half.  The stick rod worked but I could see there was a foreign substance polluting the area of the puddle.  I think it was somealuminum film smeared arround that I couldn't see.I want to Tig this next pipe but I know I need it really clean!   Yall know of any chemicals that will eat off the aluminum and not hurt the steel in thepipe ?     How about lime away or CLR type cleaners ?????I think HCL will eat it off but a little hard on the steel.   Is there a  "secret formula ? "Tim
Reply:Are you talking about welding the aluminized steel like on a car exhaust system?  I have never had to do any prep to mig weld that stuff.  It's made to be welded by exhaust system installers.  If you are talking about something exotic on your gen set, sorry I can't help you  with that.Miller Syncrowave 350Millermatic 252/ 30A spoolgunMiller Bobcat 225g w/ 3545 spoolgunLincoln PowerArc4000Lincoln 175 Mig  Lincoln 135 Mig Everlast 250EX TigCentury ac/dc 230 amp stickVictor O/AHypertherm 1000 plasma
Replycleaning Al. off exhaust tubeuog:Yeah just regular aluminised exhaust tube.  Trouble is I have several stick machinesand a new Tig machine but no mig  ( I hate mig anyway ...)When I stick welded it I could see the puddle "repelling" away from where I wantedit to go -  like a fish eye does durring spray painting.  I had ground the aluminum awaybut i think there was a film left there.I got  "pits" that I could not weld over ( like there was slag - but there wasn't )Had to be aluminum residue.......So what eats al. but not so much steel ?I may go with stainless pipe or plain uncoated steel if I can find it in the correct size.I want to tig it , to get a neat job and to practice tigging !Tim
Reply:TIG it up. In the beginning before i had a belt grinder and bandsaw I would chop it with a chop saw and then just lightly buzz it on the side of the chop saw blade (i know, not the safest thing) to get a flat cut and fit-up that you couldn't see light through. Then I would just file a little to get the burs off (inside and out) after that all that was needed was to hit it with the wire wheel (takes the coating off), and weld. Worked great for me.
Reply:That aluminized exhaust tubing is made to be welded.  If it can be migged, it should be weldable with a stick as well.  If you aren't getting good welds with your current setup, try a different rod or different setup (AC or DC , straight polarity or reverse etc).  Play with it until you find something that works.  I have never tried to tig aluminized steel exhaust tubing, and tig is much more sensitive to impurities.  My exhaust systems that I have tigged have all been stainless.  If I were to try to tig the aluminized stuff, I would probably hit the last 1/2" at each joint with a grinder.  The aluminum is a very thin coating and should come off really easily.  You'll know when you hit the steel because the aluminum won't throw off sparks, but the steel will. I know of no chemical that will eat the aluminum without also eating the steel.Miller Syncrowave 350Millermatic 252/ 30A spoolgunMiller Bobcat 225g w/ 3545 spoolgunLincoln PowerArc4000Lincoln 175 Mig  Lincoln 135 Mig Everlast 250EX TigCentury ac/dc 230 amp stickVictor O/AHypertherm 1000 plasma
Reply:I believe lye will eat aluminum and leave the steel alone. Some people use it to clean clogged files. Never done it myself though.
Reply:I just use a wire wheel.  It takes the aluminum right off.davidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Hmmmmmm  Muffler shop guys weld it everyday without any prep? They all use mig now but some still use OA.........Try that?  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock
Reply:Good fit up is far more important.  Lap joints, mig weld down hill is the easiest for me.It would be a b*tch to tig exhaust because the torch clearance thing.  I have stick welded it,  Its a feat of its own.  Get small rod.Here is a butt weld with mig.http://weldingweb.com/vbb/showthread.php?t=18426There is one with stick too. I could not find it.DavidLast edited by David R; 04-18-2011 at 05:42 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by B_CHmmmmmm  Muffler shop guys weld it everyday without any prep? They all use mig now but some still use OA.........Try that?
Reply:Clean it up with scotch bright tigs no problemVinnie
Reply:the smallest aluminised tube I could find was 1+1/2 od.I found some keyhole welded 1 inch tube used to hold cieling fans.No galvanising,just enamel on outside. (easy to get rid of- )Will make a flange and try tigging it on to a stub of this tube.  May try making a flexible section out of silicone heater hose to serve as vibrationisolation between muffler and engine.I have stick welded aluminised tube with 1/16 sheet metal rods.  it worked kind of-but the bead wouldn't go where I wanted it to.  Will try it again when I get a stickleat for the dynasty.Thanks for the helpfull ideas.Tim

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