Aluminum Handtruck Repair

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Need some advice on making this repair for a friend.It is Aluminum and varies from .350 to .400 at the crack site.My choices are to hook up the spool gun, or use my TIG (preferred).For the TIG, I don't have the amperage to do this in a single pass.Any ideas on optimal settings and prep?I was thinking of grinding a V groove, then a 3/32 at 185 amps,AC freq of 304043 fillerAC balance 80welding on both sides.Any input appreciated.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Also intend on preheating it.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Done many.  Be sure your grindng disc does not have aluminum oxide in it.  IF you can get a puddle, then go!I think 185 amps will do it.   Too small for spool gun anyhow.  You would have to preheat it because the spoolgun gets a cold start.David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:If that's what I think that is, (and I'm 90% sure from the picture), that's magnesium my friend, and not aluminum.Forget it, and buy a new nose.  They're like $40, which makes it hardly worth the time to repair anyway.
Reply:How can I tell for sure?  Scrape off a thin piece and see if it catches on fire with the OA torch?TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Does the handtruck say MAGliner on the side?They sell an aluminum nose, but not cast like that.   Their aluminum nose is bent from a piece of sheet and has no openings in the middle.
Reply:I will check when I get home.   Thanks.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Says nothing on the side.  I tried to shave a sliver off of it to test it.  Just crumbles.  Sounds like its just not worth the chance.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Hit it with a file and try lo ignite the filings with a tig torch if they burn bright white, it's magExperience is something you get right after you need it
Reply:Magnesium is as easy to weld as aluminum. Make it clean. weld it just like it was cast aluminum. the rod price will shock you.  Mac
Reply:drill two holes and bolt a piece of steel strap around  that corner..
Reply:Will the cheesy "weld Aluminum with a propane torch" rods I bought years ago be able to braze this with OA?  If I eliminate all shavings, is there any inherent danger in heating up a piece this thick?  I'm not looking for a thermite bomb here.  I do have a full ashcan available to extinguish it.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:This is easy people.Bevel it out. Grab some 4043 rod or wire. Tig or mig a tack on the end. Wait for it to crack or crack it out yourself. If it does not crack or turn green while welding, it is alum. If it does crack out and turn green while welding, it is magnesium.You can get a small lot of mag rod for tig from McmasterCarr.com.1/2lb. 3/32"36"Part#7972A82$83.98Like said earlier, mag welds like alum. Do a small section and brush clean. Repeat until done. If it catches fire, put out with inert gas from your tig torch or separate inert gas supply or appropriate fire extinguisher.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:Just be sure to get rid of any grinding dust/filings from beveling or gouging, before welding.  Like shovelon said, you will know just by striking an arc what it is, but dab some aluminum wire in just to be sure.  Cast Mg puts off some nasty smoke (from zinc, I think) when welding, I always use a small fan to blow it away.Last time I bought Mg TIG wire (about four months ago) I paid $38.50/pound, it was made by Inweld.  The LWS obviously didn't stock it but they could source it for me.  McMasterCarr seems a bit pricey.
Reply:Originally Posted by wijo0131Just be sure to get rid of any grinding dust/filings from beveling or gouging, before welding.  Like shovelon said, you will know just by striking an arc what it is, but dab some aluminum wire in just to be sure.  Cast Mg puts off some nasty smoke (from zinc, I think) when welding, I always use a small fan to blow it away.Last time I bought Mg TIG wire (about four months ago) I paid $38.50/pound, it was made by Inweld.  The LWS obviously didn't stock it but they could source it for me.  McMasterCarr seems a bit pricey.
Reply:Yeah, I was able to buy it in 1 pound quantities, 1/16" diameter.  The name of the welding supplier  is Central McGowan, in MN.
Reply:Originally Posted by wijo0131Last time I bought Mg TIG wire (about four months ago) I paid $38.50/pound, it was made by Inweld.
Reply:Originally Posted by rlitmanAnd just how many of these do you plan on fixing?  I can get a brand new shoe for this for that price, and not do any work.What's your time worth in this?What do you do if you weld it, and it fails later?  Magnesium is tricky stuff, and this part gets some serious stress.Sure, there's no harm in trying to weld it with 4043 for a hobby project, but I wouldn't bother grinding out the crack before I confirmed that it's magnesium, and if it were aluminum, the 4043 would leave it much weaker than a new part would be.