tig .020" alum?

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Fix crack in my buddy's radiator core tube for a SCCA race bucket. Used tires, used parts, duct tape...It's a poor mans league so I help him out when I can. Somebody successfully welded shut a cracked tube for him once before but now he dinged it again. No luck today using my lincon 275 sq wave. I painstakingly cleaned the area using dental picks, etc before attempting the repair using 1/8" filler and a 1/16" tungsten sharpened to a point and preheated. I weld as a hobby and that's all the small stuff I currently have on hand. I cant actually gauge the metal but compared to a feeler gauge, it's approximately .020-.030". Can it be done with my machine or is it just too big? Opinions?Last edited by badknot; 08-22-2012 at 02:17 AM."Steel is weak. What is steel compared to the hand that wields it?"- James Earl Jonesmiller 225 w/ 3035spoolmate, Lincoln sq wv 275 w/radiator, hypertherm 600 plasma cutter, other stuff
Reply:If it's one of the runners you're likely wasting your time. Braze it or epoxy it.Welding/Fab Pics: www.UtahWeld.com
Reply:That can easily be done. get some .030 filler. (a 1lb spool is probably easiest) how low does the 275 go on amperage? This video may give ya some insight on a few tips [ame]http://www.youtube.com/watch?v=eX_sepp9T_M[/ame]
Reply:why are you trying to use 1/8in filler on .020 material?ESAB MigMaster 275Miller Econotwin HFMiller Syncrowave 250
Reply:Originally Posted by BCTimberwolfThat can easily be done.
Reply:I've welded aluminum about that thin, used 1/16 Tungsten red with .030 filler. It was actually quite easy.Bear in  mind I am a novice with the TIG.
Reply:Originally Posted by steve o 77I've welded aluminum about that thin, used 1/16 Tungsten red with .030 filler. It was actually quite easy.Bear in  mind I am a novice with the TIG.
Reply:set for about 30amps and use your foot pedal and watch the puddle very closely, theres not a lot of wiggle room there if it gets hot
Reply:Keep in mind that most radiator cores are either a 1xxx or 3xxx series aluminum. If you try to use a 4043 filler on it, you will drasticly lower the melting temperature of the puddle as soon as the filler/base metal intermix, and you can cause yourself a big mess. Use 1100 filler on that and you will be much happier.
Reply:Originally Posted by badknotwhat other parameters?
Reply:Have you thought about aluminum brazing stuff? You use a torch to heat up the material and just slide the rod across it and it flows. I don't know how well it works, but from the videos it seems pretty good for stuff like that.On the other hand, i'm willing to bet 1/8 filler is your problem. I'd get some .020 or .030, Hell buy a small spool of aluminum mig wire. Any pics of the damage?ESAB MigMaster 275Miller Econotwin HFMiller Syncrowave 250
Reply:True brazing is an option, provided you use a Al/Si type filler and not a zinc based one like the flea market alumiloy rods.
Reply:It's obviously been welded before so we know it is a weldable alloy. I would personally use one of the hobart alumalloy rods if I couldn't TIG it in your situation. When used properly, they are incredibly strong for what they are. Plus it's cheap and easy to get a hold of. I always keep a lb or so for odd jobs where a TIG just aint ideal