welding unknow alum what filler

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ok welding a unknow alum aircraft part it looks billet but might be cast to  only 1/8  thick and 2 inch of weld needed to fix crack.ideas for what filler i should use ?
Reply:don't do it. if you are asking, clearly you don't have the proper experience, and you don't mention fixing the reason that the part originally cracked in the first place either.Dynasty 200DXPassport plus w/ spoolmate 100victor 315c oxy/(act and prop)Miller digital elitemilwaukee power tools
Reply:Originally Posted by Bigrich954rrok welding a unknow alum aircraft part it looks billet but might be cast to  only 1/8  thick and 2 inch of weld needed to fix crack.ideas for what filler i should use ?
Reply:Well......this is scary. You do realize that you dont just weld up cracks right?? Who is the IA that is going to sign of on that? You do realize that what you are performing is considered a major repair/alteration and will require a field approval at the very least correct? Is this a standard category or experimental aircraft?
Reply:You don't repair aircraft parts by welding. That would be extraordinarily irresponsible and negligent.The part needs to be replaced. If that's impossible, you contact the OEM. It's just that simple.
Reply:Originally Posted by JoshfromsaltlakeYou don't repair aircraft parts by welding. That would be extraordinarily irresponsible and negligent.The part needs to be replaced. If that's impossible, you contact the OEM. It's just that simple.
Reply:Originally Posted by JoshfromsaltlakeYou don't repair aircraft parts by welding. That would be extraordinarily irresponsible and negligent.The part needs to be replaced. If that's impossible, you contact the OEM. It's just that simple.
Reply:ER4043, a good general purpose Aluminum filler with silicone additives for improved flow and reduces cracking. Bright weld finish.ER5356, a good general purpose Aluminum filler with higher shear strength than 4043 and better resistance to corrosion. Recommended for use with series 5000 aluminum.Lincoln SA200's... at least 15 - 20. They come and go. Growing partial to the "Short Hoods" in my old age. Last count on Short Hoods was 13 in possession.
Reply:Originally Posted by hobohiltonER4043, a good general purpose Aluminum filler with silicone additives for improved flow and reduces cracking. Bright weld finish.ER5356, a good general purpose Aluminum filler with higher shear strength than 4043 and better resistance to corrosion. Recommended for use with series 5000 aluminum.
Reply:As a pilot and flight instructor, I'm begging you, please don't do this.  If you don't know what you're doing, you're risking my life.  It's not like a car where you can just pull over if something goes badly.  Qualifications and rules exist for a reason in the aviation world.
Reply:Lots of people use aircraft parts for other applications. You guys are all jumping to conclusions and assuming. Many people consider "aircraft aluminum" as an aircraft part.Lets see a pic to tell you if it is cast or machined and what crack your dealing with.
Reply:Originally Posted by VPTLots of people use aircraft parts for other applications. You guys are all jumping to conclusions and assuming. Many people consider "aircraft aluminum" as an aircraft part.Lets see a pic to tell you if it is cast or machined and what crack your dealing with.
Reply:I know aviation just as well. Did you read my post? He may be using the part for something NOT in a airplane.I use "aircraft aluminum" from aircraft spruce for cars all the time.
Reply:Until the OP states that it is not for aviation use, I will assume it is for the sake of safety. People have been known to lie about the use of parts to get information from people, i.e. saying that they are using XZY part on an airboat engine when it fact it is for aviation use. It might be an antique part thats being used for a coffee table, who knows, however its always safest to assume not when giving out information, especially when little to nothing is known about the application.
Reply:You know when I first read this it reminded me of one of the gear boxes on my Cessna 152. It was an aluminum part and had cracked. Though the thought of welding it never even went through my mind. It was $1200 for a used part. I had no other choice but to replace. The scary thing is someone could take a part in like this to an unknowing shop and get it Tig'd. Then throw it back on the plane like nothing happened until the gear collapses. Then you have some big questions to answer and better have deep pockets cuz I guarantee your insurance just dropped you. The OP does say "aircraft part"....not "aircraft aluminum." Sure it could be just a piece to hold in the dash on an experimental...or it could be a gear box. Hard to say, but I won't be the one to give advice on how to weld it then be held accountable when something happens to it.