What grade of aluminum

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I need to build a simple intake for a 4 cyl . There is nothing structural .So I need to know what would be the easiest to weld for some one new to tig .
Reply:1000 and 3000 series are the easiest to weld. Most Shapes are 6000 series, for your application use 4043 filler.
Reply:Dont use 4043 filler on 1xxx or 3xxx series aluminum, the dilluted weld pool will have a silicon content thats not in its "happy" region and cracking will result. Use 1100 filler on 1xxx and 3xxx material, and I would uise 5356 filler on the 6061 materials for that application. Its got higher ductility than 4043.
Reply:Well, there are a couple schools of thought to look at. The most common material is 6061. It is strong, inexpensive and commonly available. If you want to bend material a bunch, then you will want to use something from a 3000 to 5052 series material. The 1XXX-3XXX materials are very soft. And, relatively not that strong. Almost all your tube and formed materials will be 6061, or 6063 material. If it were me building it, I would use the readily available 6061, and weld with one of 2 fillers: My first choice would be 5356, second choice 4043. If I were bending up a plenum and welding it shut, I would use 5052. And I would still prefer 5356 filler. Less cracking than 4043 filler.And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:There's not really a massive difference in the weldability of the commonly found alloys. Alloy choice is going to be governed a lot by design of the intake anyway- as said extrusions are nearly always a 6xxx series, much wider choice for sheet metal but (in the UK at least) once you're into plate thickness (gasket flange) it's generally a choice of 5xxx or 6xxx series. A harder alloy is a better choice there anyway1050 or 3003 lend themselves well to forming a plenum- easy to shape, more than strong enough and will workharden some anyway during shaping. Cylinder runners typically require a little shaping, 6063 is a better choice than 6061 in that regard if reworking straight tube or preformed bends. More complicated runner shape... be fairly typically to form from 1050 or 3003 in 2 halves
Reply:Thanks ,that's the kind of info I was looking for .I was looking at 6061 for all the parts that don't need bending or forming .I just needed to know what my options were for any sizes of plate they didn't have on hand in 6061.
Reply:Food for though...All 6061-T651All 4043 fillerhttp://weldingweb.com/vbb/showthread.php...ghlight=intakeWorks great and no welds cracking or anything like that....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 second the 6061 w/4043, although most others prefer 5356. I have had more cracking with the 5356- or just the opposite of what others say. Maybe its my technique? When bending hardened use a radius 3 to 5 times the thickness to prevent cracking.Peter
Reply:Originally Posted by castweldI second the 6061 w/4043, although most others prefer 5356. I have had more cracking with the 5356- or just the opposite of what others say. Maybe its my technique? When bending hardened use a radius 3 to 5 times the thickness to prevent cracking.Peter
Reply:Zap, that manifold should have been made into a table or something. it is a work of art. absolutely beautiful and a testament to some wicked azz skills.http://kawispeed.com/ -moderator and tech deluxewww.myspace.com/trickortrack -cuz i have no life
Reply:Anodising 'sticks' just fine to 4043, although the welds will stand out like a sore thumb especially with light colours. Very basically it's just a cultivated/artifically thickened oxide layer...  http://www.aws.org/wj/2008/04/wj200804/wj0408-22.pdfThe addition of silicon lowers the melting point of 4043 (even lower again for 4047) which is why it's generally more 'crack resistant'. The weld freezes over a wider temperature range. The risk of solidification cracking depends on the composition of the weld- silicon, copper, mag can all give rise to cracking issues if the composition falls into the right range... aluminium solidification cracking. As the link shows, silicon has the narrowest range butdepending on base alloy and weld dilution cracking can still be an issueThis is one of the reasons why it's not as simple as 4043 for billet (wrought) and 5356 for cast etc
Reply:Originally Posted by whitehendrix!Zap, that manifold should have been made into a table or something. it is a work of art. absolutely beautiful and a testament to some wicked azz skills.
Reply:I found a candy store that has all sizes of 6061 that I needed by the inch.2x6 for torque plate1x3.5   base plate.5x3.5  plenum baseThe runners I have not figured out yetI have 4043 so I will go with that .But I might get some 5356 to try my hand on the stock intake first .   Didn't have use for the link to the intake pics.........Because I saved the originals and have admired you work  for couple years . Hopefully I have a dime or two left so I can take pics.
Reply:Originally Posted by RojodiabloWell, there are a couple schools of thought to look at. The most common material is 6061. It is strong, inexpensive and commonly available. If you want to bend material a bunch, then you will want to use something from a 3000 to 5052 series material. The 1XXX-3XXX materials are very soft. And, relatively not that strong. Almost all your tube and formed materials will be 6061, or 6063 material. If it were me building it, I would use the readily available 6061, and weld with one of 2 fillers: My first choice would be 5356, second choice 4043. If I were bending up a plenum and welding it shut, I would use 5052. And I would still prefer 5356 filler. Less cracking than 4043 filler.