Welded Aluminium to Steel

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Had a piece of TSA'd steel for testing purposes lying around and thought it would be fun to try it. Used 5356 filler, TSA aluminium is 99,5% Al. Maybe not the best combination but it's weldable as you see.
Reply:You can successfully apply weld metal to the material, but that is still a long ways from welding.
Reply:cool, how thick is the TSA layer?--------------------------------------------------------------www.becmotors.nlyup, I quit welding.. joined welder anonymous
Reply:Originally Posted by Rock knockerYou can successfully apply weld metal to the material, but that is still a long ways from welding.
Reply:It is akin to welding the paint together.
Reply:TSA (Thermal Spray Application) is what the OP is talking about:http://www.metallisation.com/process/ElQuapo - How thick is the TSA aluminum surface and is the bond between it and the steel strong enough to prevent tearing away after welding?MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Wasn't expecting miracles like fusing the metals, it was just a try to know if it would work in case I might actually need it.The TSA aluminium base is for corrosion protection only. There's about 250 micron's applied. Base metal is gridblasted to 120microns minimum roughness which will hold the aluminium. We need 5MPa, that's why the round patch is on the piece. It's 2K glue which holds a dummy for a pull-off test. The glue let go at 11MPa, guess the aluminium does a bit more than that but I fear the welding decreases the quality.Already broke the piece clean off to the metal by bending it, maybe a straight pull-off will do a bit more. At least it will cause some head scratching
Reply:That could be useful for sealing against corrosion, though a lower temperature "solder" method might be better."USMCPOP" First-born son: KIA  Iraq 1/26/05Syncrowave 250 w/ Coolmate 3Dialarc 250, Idealarc 250SP-175 +Firepower TIG 160S (gave the TA 161 STL to the son)Lincwelder AC180C (1952)Victor & Smith O/A torchesMiller spot welder
Reply:Originally Posted by ElGuapoThe TSA aluminium base is for corrosion protection only.
Reply:you need to get some of the blast welded plate to try that with. you'd have much greater success.There are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger
Reply:No doubt on the explosion welded plate.It's just an interesting subject "experiment" and I'm curious is all.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!