Filler for TIG 6061

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I'm looking to make an aluminum divider for a pelican case. I'm still a novice at best with TIG and I've done aluminum once.I have a filler rod I picked up local not sure what it is off hand.Anyway I am looking to order .125" x 3" 6061 flat bar online. What's my best bet welding this? Also, is it worth making full beads on this, since it's just a divider?www.FirehouseFabricators.comZachLincoln 210mpLincoln SW200Hypertherm Powermax 45xp2x4 CNC Plasma Table.
Reply:It's not critical so the filler rod could be 4043 or 5356. A continuous weld could cause a lot of warping.
Reply:ting the correct filler alloy for aluminum is based on the operating conditions of the finished welded component. It istherefore essential to have the answers to some basic questions prior to the selection of the most appropriate filler metal.1. What is the aluminum base metal designation?2. Will the welded component be exposed to sustained elevated temperature?3. Will the completed weldment be subjected to post weld anodizing?4. Will shear strength, ductility, and toughness be of prime consideration?5. Is post-weld heat treatment to be performed?Alloys 4043 and 5356 are used in over 85% of all aluminum weldments. If the technical requirements of the weld canbe met with either 4043 or 5356, use one of these two alloys because they are readily available and are the leastexpensive to purchase. Also consider using the largest recommended diameter wire because the larger sizes are alsoless expensive.When welding the 5xxx and 6xxx series base metals the following considerations should be made when selecting themost appropriate filler metal:• For 6xxx series base metals, and 5xxx series base metals containing less than 2.5% Mg use either 4043 or 5356.• For 5xxx series base metals containing more than 2.5% Mg use 5356 filler metal and do not use 4043 filler metal.• For good anodized color matching use 5356.• For higher ductility and toughness use 5356. This will increase resistance to crack propagation.• For long term elevated temperature exposure above 150°F use 5554 or 4043. Do not use 5356.• For higher shear strength use 5356. A rule-of-thumb is that it takes three fillet passes of 4043 to equal the shearstrength of one pass of 5356.• For reduction of termination and shrinkage cracking use 4043 or 4047.• For reduction of welding distortion use 4043 or 4047.• For brighter welds with less welding “smut” use 4043.• For better feedability through the welding gun use 5356. 5356 is twice as stiff as 4043 and therefore feeds better.However, MAXAL’s 4043 has excellent feedability.Note: For more detailed information on filler metal selection refer to the MAXAL selection chart in the back of this book.Filler MetalGuidelines For Selecting The Most Appropriate FillerOf all the things I lost I miss my mind the most...I know just enough about everything to be dangerous......You cant cure stupid..only kill it...
Reply:http://bit.ly/1zvNEyKyou're welcome  1st on WeldingWeb to have a scrolling sig! HTP Invertig 400HTP Invertig 221HTP ProPulse 300HTP ProPulse 200 x2HTP ProPulse 220MTSHTP Inverarc 200TLP HTP Microcut 875SC
Reply:What is a pelican case? And look at the ends of the rod you got. should say a number on it. Post pics of your project and welds!
Reply:Moto: Google 'pelican' cases. Brooklyn : 4943 or 5356 will work in critical or non critical situations. Just depends on being anodized or not.
Reply:Besides the army ranger that is carrying his rifle in a pelican case to go find the head guy of Isis gang and take him out I don't think it matters what rod you use. On 2nd thought you might wanna run a bunch of beads on scrap AL before you take the time fabbing up a nice case to ruinLast edited by motolife313; 02-21-2015 at 04:04 PM.
Reply:I picked up these cases and I am going to use them to make an emergency kit to keep in my jeep.Totally overkill, they just look cool Purchasing a divider setup is like $90. Rather build a sturdy one.You think a half inch weld top and bottom on either side is sufficient? There is 0 weight being put on these. Literally walls to hold in road flares medical supplies and tools.Last edited by BrooklynBravest; 02-21-2015 at 04:10 PM.
Reply:Originally Posted by Oscarhttp://bit.ly/1zvNEyKyou're welcome
Reply:Clamp it as good as you can and weld the thing up best you can. You will have to learn from experience not just what people say
Reply:Originally Posted by BrooklynBravestI'm looking to make an aluminum divider for a pelican case. I'm still a novice at best with TIG and I've done aluminum once.I have a filler rod I picked up local not sure what it is off hand.Anyway I am looking to order .125" x 3" 6061 flat bar online. What's my best bet welding this? Also, is it worth making full beads on this, since it's just a divider?
Reply:Originally Posted by BrooklynBravestI picked up these cases and I am going to use them to make an emergency kit to keep in my jeep.Totally overkill, they just look cool Purchasing a divider setup is like $90. Rather build a sturdy one.You think a half inch weld top and bottom on either side is sufficient? There is 0 weight being put on these. Literally walls to hold in road flares medical supplies and tools.