Weld SS304 Hardware to Aluminium

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Hi! Many of my customer's drawings require SS304 Studs/Nuts/Bolts to be welded on to Aluminium 6063 sheets (1.5mm / 2.5 mm / 3.0 mm thick). Is it possible? How do we do it?I have a Fronius MagicWave 2200 TIG machine and a DIN 286 qualified welder.
Reply:I think all you can do is braze it with oxy/acetylene...MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:You should have a long serious talk with your customer. You should be able to braze the stainless to the aluminum. I think someone made an error.
Reply:I have help build some large kilns for drying lumber. They are all aluminum and SS. In all the drawing I have seen, The show SS bolting hardware but it is never welded to the aluminum. I think it would be a complete waste of time and money to braze the SS hardware to the aluminum if it even possible.Miller DVI2Lincoln Precision Tig 225Thermodynamics Cutmaster 38Everything else needed.
Reply:Oh it's possible, and not as uncommon as you think to braze stainless to aluminum......but unless they need something leak proof I wonder why? Or even what kind of 'hardware" they are talking about.
Reply:Originally Posted by makoman1860Oh it's possible, and not as uncommon as you think to braze stainless to aluminum......but unless they need something leak proof I wonder why? Or even what kind of 'hardware" they are talking about.
Reply:TIG weld?  Nope.Braze?  Possible.Friction or explosive weld?  Possible.Sometimes the customer doesn't know what they are talking about or asking for.  Sometimes you have to educate them.  The best laid schemes ... Gang oft agley ...
Reply:i had a friend asking me if i can weld a piece of aluminum onto redwood.you mean bolted?no, welded, weld the aluminum to the chair to strengthen it.er, no.  i dont think thats possible.c'mon, i thought you were all into welding and stuff.
Reply:SS to aluminum No they are metallurgically highly imcompatible.  you can get aluminized steel which has been coated in aluminum. It's possible to weld that to aluminum, if not a little difficult.If it's aluminum obviously corosion isn't an issue so without seeing it, I'm at a loss for why Stainless steel was chosen. Often times some purchasing agent or whoever will pick what is cheap thinking that aluminum fasteners are too expensive and they are saving the company a buck, not realizing the difficulty in trying to weld mixed metals.Brazing is your best bet followed by adhesive bonding.If they are wanting to use studs and nuts on sheet.  They should look into  stud welding etc. I believe they make aluminum studs and bolts for stud guns.Welding EngineerCertified Scrap Producer
Reply:Thank you everyone for your expert views! Even I was sceptical about this process but my customer (a BIG company into European railways) was mentioning it again and again, I thought I might be missing something!They are actually looking for aluminium sheet metal components (out of 3mm thick aluminium) and they want SS304 fasteners (nuts and bolts) to be actually welded to the Al. sheet so that they can later on fix it to the body of the coaches.It seems after your replies that I really have to approach them for drawing deviations - rivet nuts/studs instead of welding.Thanks again!
Reply:Look at a PEM nut, or PEM stud. They are pressed into the sheet and provide a threaded feature. Very common in sheet metal parts. These are availible from http://www.pemnet.com/. -DanOwnerDW Metalworks LLCMiller Trailblazer 302Miller 8RC FeederMiller Passport PlusMiller Dynasty 200 DX W/Coolmate 1Hobart Handler 135Hypertherm PowerMAX 30Smith O/A Torch SetPlus much much more
Reply:Originally Posted by rishiThank you everyone for your expert views! Even I was sceptical about this process but my customer (a BIG company into European railways) was mentioning it again and again, I thought I might be missing something!They are actually looking for aluminium sheet metal components (out of 3mm thick aluminium) and they want SS304 fasteners (nuts and bolts) to be actually welded to the Al. sheet so that they can later on fix it to the body of the coaches.It seems after your replies that I really have to approach them for drawing deviations - rivet nuts/studs instead of welding.Thanks again!
Reply:Originally Posted by engnerdanLook at a PEM nut, or PEM stud. They are pressed into the sheet and provide a threaded feature. Very common in sheet metal parts. These are availible from http://www.pemnet.com/. -Dan
Reply:Rivnuts would be a much better option.    I think something is getting lost in the translation possibly.Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.