Aluminum problem

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I have a  cast aluminum pump body that needs to have one of the bores welded because it is over sized.  Paperwork for the part calls for 4043, even checked with the engineer to be sure.  I cannot get a puddle started to save my life.  I have tried using Pure up to about 110 apms  tried 2% up to about 140.  I can only get a puddle going to with 2% at around 130 amps.  When I add filler it looks like someone poured water on it, very porous and filthy.  Any ideas?NitroJay
Reply:cast aluminum calls for 5356i dont care what the paperwork says  castings are the toughest things to do anyway..and if you never have done one before well then your in for many headaches..how big is this bore?cant you make a sleeve and press it in?pics or more info would be helpful.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:I know that cast calls for a different filler thats why I asked the Eng.  I have welded several similar parts but not this one.  The bore is only 1\2" and is already over sized for a bushing.  I normally do not have a problem getting a puddle started with this type of aluminum pump but this one is really not being very nice to me.  I would take a pic but no cameras allowed here.NitroJay
Reply:Is the pump body porous? What is the thickness of the body? Is the body ground shiny & clean?(the area to be welded)If it's more than about 3/32" thick, you might need more amperage to get it flowing . Are you using argon or helium , for coverage ? All this stuff matters, but you PROBABLY know this .[SIZE="5"Yardbird"
Reply:Pump is very porous, never have seen one this bad.  I finally got it.  Weld and grind weld and grind...I ended up using %2 tungsten, argon and helium.  Helium flow at 2 and argone at 30, and still used 4043.I put alot of hours into but it's good, I got it out of NDT this morning all is well.  NitroJay