Butt Welding - TIG

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Back at it again, this time I tried to weld two pieces of 1/8" 6061 aluminum together. I cleaned both pieces with S/S wire brush - pushed them together as close as possible, then used the ground clamp to kinda hold them in that position.  I welded 3/4 of the piece until I got close to the clamp and then switched it and completed the bead.  I then cooled the piece down my putting it in the snow outside my garage (I'm in Iowa; raining/sleetling like crazy) - anyways, I then put the piece in a vice and nailed it with a hammer; and guess what? Just snapped right off.  I read somewhere that when butt welding that I should put some "space" between the two pieces?  Is this true? If so, how much? Also, should I weld the other side?  Imagine this would increase the strength?ThanksAcademyKP03Miller Sychcrowave 200
Reply:I think you need a space or better a bevel.  Were you using filler?Yeah, weld both sides.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Yes, I was using filler, but didn't bevel - and I only welded one side.  However, I thought that if it was a good weld, then the 2nd side wouldn't matter .. am I wrong?  guessing 2nd side was a 2nd safety factor ....AcademyKP03Miller Sychcrowave 200
Reply:Got any pics?DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Sorry, no pics, I ended up using the other sides and attempting a 2nd time, ended with same results (broke off).  Next time I'll bevel the edges - and the other side.  speaking of - welding both sides, is that standard practice?AcademyKP03Miller Sychcrowave 200
Reply:Welding both sides depens on the aplacation. If you do a small beval on both sides say 1/4 of the thickness and weld you will basicly have 100% penitration. If you bevel say 90% and weld on one side you get 100%. Idealy you want 100% this is rarly the case but it is ideal. I have left a gap and welded a cap weld over the gap and then turned it over and ran down the gap and it gives you about 100% but this is slow and I prefer beveling. Remember when gringing or sanding aluminum use aluminum grinding and sanding pad or the gronding compound will foul your welds (aluminum oxide) and it will prevent loading and therfore be safer to use. Steel Thunder Welding LLC. St. Thomas VI USAMM350PBOBCAT 3MAXSTAR 150 STH375 EXTREME PLASMA6.5 HP COMPRESORDEWALT 18, 24, AND 36 VOLTO/A TORCH SETAND SO MUCH MORE I DONT REMEMBERALL IN MY 2005 2500HD EXTENDED CAB L/B
Reply:Short comment.6061 requires filler metal, without added filler metal it will crack.5356 filler for good strength if the weldment will not be re-heat treated after welding.4043 filler if post weld heat treating, it will provide a weld chemistry mix with the 6061 that repsonds to heat treating.Quenching Aluminum after welding is not a problem, it does not harden and become brittle as carbon steel does.
Reply:Is there a way to look at 4043 and 6061 and tell the difference? I just welded a catch can for a race bike without any filler. No cracks (yet) and welded really easy with no filler. Picked it up at the local steel supply place. Is one type more common than the other that is sold at the local steel supply houses.
Reply:Originally Posted by kshellrazorIs there a way to look at 4043 and 6061 and tell the difference? I just welded a catch can for a race bike without any filler. No cracks (yet) and welded really easy with no filler. Picked it up at the local steel supply place. Is one type more common than the other that is sold at the local steel supply houses.
Reply:Thanks, so if I welded a catch can without using filler and the type is 6061, will it crack down the road? It is not under any pressure or stress. It just sits in the bike frame and catches gas and fluids if you crash. It is never in any direct contact even if you crash. I also welded a catch can on my bike, just fused it, and have never had a problem with cracking.
Reply:Originally Posted by kshellrazorThanks, so if I welded a catch can without using filler and the type is 6061, will it crack down the road? It is not under any pressure or stress. It just sits in the bike frame and catches gas and fluids if you crash. It is never in any direct contact even if you crash. I also welded a catch can on my bike, just fused it, and have never had a problem with cracking.
Reply:Originally Posted by RojodiabloIt's not a stressed part. I raced VFR's, Hurricane 600's, an RC30, an rs250. I know exactly what you're talking about. When you mounted it, it has either tabs on it, or it is hose clamped to the frame somewhere. Just put a small sheet of 1/16" or 1/8" sheet rubber or foam, something to take up the vibration. You should be fine.
Reply:Originally Posted by kshellrazorCool. Thanks for the answer. RC30s were sweeeeeet. I saw one in Daytona a couple years ago. Those things are timeless!!