TIG Welding Plasma Cut Aluminium Parts?

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Hi all... I'm looking to consistently fabricate some aluminum tanks. Not a large volume but a few every month. Each tank has its own custom dimensions and more than likely no tank will be made more than twice. Our options as they have been presented to me are purchasing a cnc plasma cutting table which will make it cost effective and easy to cut any configuration in house or outsourcing them and having them water jet.What I'm looking for is information on welding plasma cut aluminum parts. I was told that for steel its fine to just jig and weld but for aluminum the surface needed to be ground or etched with a chemical before prepping and preparing the surface as you normally would for welding.We'd like to keep it all in house, and the cnc plasma is the most cost effective, however if its more trouble than its worth then we'll need to look for other options.Other useful info: I am the one designing the tanks not the one welding them. The material is 5000 series 1/8" thick.Thanks,~Colin
Reply:usually after a plasma cut on Al you should grind the surface lightly. --Gol'
Reply:Amen to the above. You should abrade lightly, wipe with acetone, and weld.If you do not have to remove any kerf/swarf you should be able to use a clean stainless brush rather then a grinder. Lastly fan a small torch over the area your going to weld and if you see the area begin to "sweat" just a bit, that would be the moisture in the material and you should then preheat the areas you going to weld to drive out the moisture to minimize the chance of any porosity in the weld.ric
Reply:If you are going to be doing gas tanks you should get a shear, and a  break. Because that is about all you will ever use. For the little holes you are going to be putting into the 1/8 aluminum you can use a hole saw.I cut and bend them up all the time. Many of the tanks we make are done with three pieces of metal, one large piece that makes up an odd shaped tube, and two ends to seal it. It can be a bit hard to get them out of the Roto-die, or break. But it is possible. There are the baffles of course to that add to the number of pieces of metal in the tank. Some cannot be done like this, and require a two piece main body. But it can all be sheared.        Sincerely,             William McCormick
Reply:Yes you can cut with plasma, but need to dress the cut before welding.  Use a wheel or disk that does NOT contain aluminum oxide.   Read Made For Aluminum.David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Second a shear and brake....
Reply:Are they going to be made of angular pieces that can get cut on a shear?  If not  get a plas cutter.  If they are going to be square or rectangular tanks then get a brake and shear.Have we all gone mad?
Reply:These are liquid storage tanks. They are extremely intricate, some with compound angles many with at least 5-7 planes. shearing is not really an option.  Thanks for everyones feedback.~Colin