TIG Welding Cast Aluminum To 6061 Sch40 Pipe Tips

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Hello all, I have a nice little piece work project to do and I need a little advice. I have to weld a cast aluminum fitting to a short piece of 6061 1.5" sch40 pipe. I am using 5356 filler with pulse on my Everlast 355 EXT, I am preheating the cast fitting and have a positioner to hold the work piece. My main question is what temp do i have to heat the fitting to? Should I try and abrasive to clean the surface a little prior to welding? What other tips do you guys have for welding cast to pipe? I read another post that said you should take a pass with out filler wire to clean out imputities and then run a pass with filler wire. THis is the part prior to wleding This is an image of what they are looking for in weld finish. That to me is a very tight hot bead that looks autogenous to me as tight as it is, am I wrong? Thanks for you help.
Reply:If you know 100% that that particular casting can be welded (and I would verify that in one way or another) I would use a Carbide burr or a file (one that is specifically dedicated for aluminum) to clean up the casting. I would heat it to about 150°F.  That's really all you have to do.
Reply:Thanks! I did try and weld a bit on the bottom of one of the casting and it welded fine but there was some contamination floating on top of the weld when it coolded. I ground off that weld and tried again on the same piece with better results but not as good as I would like. I will clean them up a bit with a file prior to swelding. I don't have any dedicated aluminum burs at the moment so don't turst those. Does not sound like a scotch brite would be enough to clean up the surface?
Reply:That picture isn't in focus, but it looks like filler was used.Check out my bench vise website:  http://mivise.comMiller Syncrowave 250DXMillermatic 350P with XR AlumaProMiller Regency 200 with 22A feeder and Spoolmatic 3Hobart Champion EliteEverlast PowerTig 210EXT
Reply:Originally Posted by WeldedSpoonThanks! I did try and weld a bit on the bottom of one of the casting and it welded fine but there was some contamination floating on top of the weld when it coolded. I ground off that weld and tried again on the same piece with better results but not as good as I would like. I will clean them up a bit with a file prior to swelding. I don't have any dedicated aluminum burs at the moment so don't turst those. Does not sound like a scotch brite would be enough to clean up the surface?
Reply:They turned out well, not big iusse. Thanks for the help all!
Reply:Looks like a job well done.
Reply:Did turn out nice! Just curious, what did you finally decide to clean the cast?GeezerPower Mig 255C185 TIGBlue 175 MIGRanger 8 Kohler 20HP1974 5K Lincoln/Wisconsin Powered (Cherry)Victor/Harris O/AK 487 Spool Gun