Weld an "Aluminum" Tree Pruner Head?

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Am trying to weld a junk metal "aluminum" tree pruner head and having no success.Using a Dynasty 280 set to ac. 3/32 2% lanthanated tungsten. 120 amps. 70% balance. 145 hz. 18 cfh. #7 gas lens.When attempting to weld the tungsten glows purple, is destroyed & black smoke covers the cup inside & outside.The "aluminum" has a white ash deposit on it. Additionally, the arc wants to drill a hole in the "aluminum".The material was sanded, filed and cleaned with non-chlorinated brake cleaner. It's about 1/8" thick.What gives? Sure would like to repair this as opposed to buying a new part.







Millermatic 255 Dynasty 280 DX TIGRunnerReady Welder IHypertherm 30XP
Reply:

Originally Posted by robert-r

Am trying to weld a junk metal "aluminum" tree pruner head and having no success.Using a Dynasty 280 set to ac. 3/32 2% lanthanated tungsten. 120 amps. 70% balance. 145 hz. 18 cfh. #7 gas lens.When attempting to weld the tungsten glows purple, is destroyed & black smoke covers the cup inside & outside.The "aluminum" has a white ash deposit on it. Additionally, the arc wants to drill a hole in the "aluminum".The material was sanded, filed and cleaned with non-chlorinated brake cleaner. It's about 1/8" thick.What gives? Sure would like to repair this as opposed to buying a new part.








Reply:Yep. White fluffy powder. Thanks.So... how would one weld cast zinc?
Reply:Rule number 1 when dealing with zinc: DO NOT BREATH THE FUMES!!! It'll make you sick. Been there, done that.Anyway, since you're using TIG, maybe try to fusion weld it first. Not 100% sure what to use a filler, since I'm unsure of the alloy. Can't hurt to try some aluminum filler. You could also try low temperature aluminum brazing rods and a torch with a small tip. If it's a high zinc alloy, you probably won't have a lot of luck with TIG (I'm just guessing at that). Zinc vaporizes at a fairly low temp. Especially compared to aluminum.Sent from my Lincoln Buzzbox using Tapatalk