TIG process for aviation welding

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Hi everyone.Hello from Paraguay, South America.I have a welding company that works in MIG, TIG and stick arc welding process.Currently we´re on the investigation of how to manage the process of welding a Cessna Engine, specifically the Continental 520 engine, that have a crack block.This repair is common in the US, and many of the airplanes (cessnas and beechcrafts) that had that very common issue get repair , but this cost a lot of time because it had to be send to the US from south america.The bolck itself is made from aluminum, but we´re not sure if its only aluminum or a combination of aluminum and magnesium.If anybody knows that, will be gratly apreciated.We work with ESAB machines, MIG 380volts 316amps and SUMIG TIG 380 volts Inverter 350 amps.
Reply:I would call/e-mail Cessna to get 100% info on the right process because of the metal working properties on such a critical area. What area of the block is cracked? Good luck!
Reply:I am fairly sure the O-520 is only aluminum but I would check with Continental, as to welding it it all depends on where the crack is. There are a number of places that 520s crack some are not a big deal some are. If you could describe where the crack is and a picture is better. Now it would be better if you contacted a repair station in the US. As you know that kind of welding falls under the regs here in the states...BrandonLincoln Tombstone 225 A/C Steel StickerOld Victor O2/Acetylene setupMiller Syncrowave 250 Tig/PC-300 PulserMiller Millermatic 212 Mig HTP Invertatig 201 Giant Teck D50 Plasma cutterLots of HF grinders
Reply:Thanks,I will take a pic and posted here. There is a guy here that fill the cracks on the O520 engines, but he "just fill", no regs aplied, no process aplied, no nothing. So, my goal is to get all the specs for the right process and norms, so I can get a certification for South America in Aviation welding. I will also get a Ultrsound machine to verify the penetration.Any info would be apreciated.Brandon113...do you know who can I e-mail at US ...any repair station with good reputation that you know?Thanks. Raul.
Reply:I¨m pretty sure it is aluminum 6062. Filling with 4043 should be ok???...or 5053 ?
Reply:Sorry, 5356 filling...and the aluminum should be 6061.....we only have available in this country 5356 or 4043 fiiling ....anything else got to be imported from abroad.
Reply:Ok Stop, just stop. You have listed a base alloy that's wrought, not cast. Your way off base. Cessna isnt going to have technical information on the engine, thats up to the engine manufacturer. In this country that would be considered a major repair and a 337 or field approval required. Or if your a repair station you will have your certification to do EXACTLY that repair. However I doubt a repair station will give out any technical information for obvious reasons. Have the alloy determined for the case, do the research, and make the repair correctly, if its even possible, using a correct process, materials, and techniques. Its likely that the case will need to be re-machined after welding. If you dont have the capability to determine the alloy and the correct process for repair, and are coming on a chat board for engineering advise, please DONT repair the case, and have a certified shop do it for you. Lycoming or Continental will NOT give you advise on welding, as they DONT approve of it, and for good reason.
Reply:Well, that is not quite true, He is in South America and not covered by the FARs and doesnt need a 337 or a field approval which our FAA doesn't hardly do anymore. Makes it hard to sell in the US though. I have farrier in a few scary airplanes from there and yeah the logbooks were a mess. What you say makoman is true but then again it is not that easy to ship your case back to the US with all the stupid inport/export laws. and yes there are a few repair stations that work with people in South America that do just what he is asking for.Lincoln Tombstone 225 A/C Steel StickerOld Victor O2/Acetylene setupMiller Syncrowave 250 Tig/PC-300 PulserMiller Millermatic 212 Mig HTP Invertatig 201 Giant Teck D50 Plasma cutterLots of HF grinders
Reply:Brandon, Thats why I said, " In this country".  Maybe where you are from you dont to FA's and such, but here they are very common, and I wold like to know how your getting around them. Our local office has a large engineering staff, and provided YOU do the engineering ahead of time, having a modification or repair approved takes a matter of a couple days. The process is not there to make life difficult, its there to force people to prove what they have done is safe. Usually the only people I have met that dont like/use the system, are those not capable of understanding the repairs they are making, and truthfully shouldnt be making them. Now Im not saying that "under the table" work doesnt go on, it does all the time, but it doesnt make it right. ISo are you and A&P, an IA, or ?? Quite frankly I dont give a #### what they do in South America, they dont have any controls, and let anyone do anything they want just about. When you have someone quoting wrought alloys for a casting that sends up a big red flag for me, not only about aviation, but in general knowledge of metalurgy. Not saying they couldnt be capable of a repair in the future, but they are nowhere near ready at this point. Id like to know of the repair stations that hand out information, I personally have never seen one, at least a good one, that would even think of it.
Reply:Yeah I don't disagree with you, I don't think the guy asking the question was the A&P and sure some of the answers were wrong but the guys just need to find a RS in El Paso or Brownsville that will work with em. And you know yourself this is not like welding up a burner can. 520 cases crack along the top flange and can be welded and as long as the crack is within tolerance. Just so long as it is not on a mounting lug or somewhere else that is high stress. Yes I am an A&P/Pilot and the reason that I have not given the guy names of repair stations that will work with em cause I don't want to get anyone in trouble. There are way too many inspectors out there that never turned a winch in anger that are looking for something to do, damn paper pushers. Also you know Aviation is dying right now and a little kinder and gentler would work.....Lincoln Tombstone 225 A/C Steel StickerOld Victor O2/Acetylene setupMiller Syncrowave 250 Tig/PC-300 PulserMiller Millermatic 212 Mig HTP Invertatig 201 Giant Teck D50 Plasma cutterLots of HF grinders
Reply:Ok.....Just for the record:I had lived in the states for many years, and I know that not everything is under control there...even aviation....I have seen mexicans guys  with funny FAA papers working on planes in Florida...so i don´t said here is a control paradise either, but lets get honest please.If i asked about the alloy of the IO520 is because I want to be 115% sure of what I´m doing....and if makoman think that this is my only resource for info...well you very Wrong my friend. Another thing...I´m not average welder by the south american standars....not every weld shop have a Ultrasound and RX machine for penetration check up...and I do....thanks anyway....I will repair the block.. the work will be certified by the manufacturer, and the plane would not fall...at least not from a cracked block.
Reply:That's fine Techsold and I know that since you know what you are doing it will be fine. And yep you are right things here are not completely under control. lots of folks around here get rapped around the axle. 400 series Cessna's are tough old birds and fly fine on one engine anyway......that is a joke by the way....Good luck to you TechsoldLincoln Tombstone 225 A/C Steel StickerOld Victor O2/Acetylene setupMiller Syncrowave 250 Tig/PC-300 PulserMiller Millermatic 212 Mig HTP Invertatig 201 Giant Teck D50 Plasma cutterLots of HF grinders
Reply:Well, no offense but I dont aggree with all the "under the table" work. And im sorry if I insulted your welding ability, but you have to realize, when someone thinks a casting it made from a wrought alloy....it does sound like a lack of education.
Reply:Sure I do understand, just there is a lot of pencil whipped log book here and yep that can lead to an accident. And I try to help those guys out down there....Lincoln Tombstone 225 A/C Steel StickerOld Victor O2/Acetylene setupMiller Syncrowave 250 Tig/PC-300 PulserMiller Millermatic 212 Mig HTP Invertatig 201 Giant Teck D50 Plasma cutterLots of HF grinders