Q: How to weld steel and aluminum together?

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Anyboady here have recommendations as to how to weld aluminum to steel/steel to aluminum?  How's it done? Im ASSuming GTAW.ThermalArc 185MillerMatic 180 w/ AutosetVictor Cutskill Oxy/AcetyleneThermal Dynamics Cutmaster 38and spite!
Reply:They make things called nuts and bolts, as well as, rivets.  It's tough to get ferrous and non-ferrous welded together.John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Is this a trick question?(loud buzzer sound here for about 5 seconds)No!!!!! It cant be done..    Unless like I have stated before..With the right rpm and oil pump failure  ...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:Hey Zap, you CAN do it in a different way than what you stated. Last year, I successfully welded aluminum and steel together at 7600 RPM when one of the cams in my 928S4 lost oil to a cam bearing! Damn regulator valves.
Reply:Friction welding only.Can't be done with fusion welding.Last edited by TSOR; 03-28-2007 at 11:06 PM.
Reply:glue it
Reply:Good to know.  Had some nut from craigslist come by today saying that he had stick welded cold steel and aluminum together.  Got me to thinkin'...wha?Was wondering what rod!ThermalArc 185MillerMatic 180 w/ AutosetVictor Cutskill Oxy/AcetyleneThermal Dynamics Cutmaster 38and spite!
Reply:Can't be done as others say. Perrhaps some ancient alchemist has a formula, though.......the fellow on Craig's List must be a Miller Millermatic 252Miller Syncrowave 200Liincoln AC-DC 225Victor O-A Set
Reply:: How to weld steel and aluminum together?
Reply:You could probably do it with a friction stir machine, it's sort of a high tech version of a water pump, but faster and more accurate. Not to mention that it can be used for more than just sticking impellers to housings.I did try it once with my mig. just for laughs, ended up just making a mess of the alluminum.
Reply:Originally Posted by SLAGJust have Zapster breath on it.
Reply:It must be all of that SPAM you eat zap!!   Here is the only easy way to weld aluminum and steel together: - Paulhttp://all-a-cart.comWelding Cart Kits and accessories
Reply:Didnt some fella post something about flash welding, plunge welding, something like that,  the two together (he was in the navy, and was talking about ship repairs)Various GrindersVictor Journeyman torch200cf Acet. 250cf oxygenLincoln 175 plus/alpha2 gunLincoln v205t tigLincoln 350mpEsab 650 plasmaWhen you can get up in the morning, Its a good day.Live each day like its your last.
Reply:This is what you get when you weld, or try to weld, mild steel to alum.sorry bout the lousy pics---I'm a better weldor than photographer. Attached ImagesLast edited by TEK; 03-29-2007 at 04:16 PM.
Reply:Works good now don't it??...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:It can be done.  I have proof, you guys just don't know how to do it.For that matter, neither do I.I have some Keystone wheels from the 80's that have the inner hub (cast aluminum) welded to the outer steel rim by obvious welded fillets.  I've pondered over those welds for 20 years, and have no clue how they did it, but they did- and in a production setting.Hobart Stickmate LX AC/DC, Millermatic 252 & 30A spoolgun, Thermal Arc 185 TIG, Miller BWESmith Oxy-AcBridgeport 2J , South Bend 42" 9AHusky 7.5 HP 22.3 CFM 80 gal compressor
Reply:Could they be brazed? I did a little brazing in an auto body repair class about 10 years ago, but I don't think we brazed al, so I don't know if it's possible.
Reply:Originally Posted by TEKThis is what you get when you weld, or try to weld, mild steel to alum.sorry bout the lousy pics---I'm a better weldor than photographer.
Reply:Joining aluminum and steel is very common but very complicated.  If one googles explosive welding one will find all kinds of information.   I have seen samples of joints.  The sample block showed the blast ripples on one side but on the adjacent side where the saw cut was ninety degrees you could not see evidence of the blast wave.    Strips of this manufactured plate are welded to the steel deck of a ship then the lighter aluminum superstructure is welded to the aluminum side of the strips.   At one time this was high tech cold war stuff.  You definitely have to know your explosives to join aluminum to steel.
Reply:And, if you are trying to get a close up, on top of your camera is a little flower icon- that is for macro. With macro, you will be able to get close ups in focus as close as 3" from the workpiece.
Reply:You definitely have to know your explosives to join aluminum to steel.
Reply:Originally Posted by zapsterWoW!!! Count me out...zap!
Reply:Rojo- thanks for the tips bud. I do know that stuff but sometime I get too impatient and dont care. That was a good example.
Reply:I think the LNG tankers with the big dome are, an AL dome to a steel hull explosion welded. There was an artical in "The Fabricator" about a year ago on joining dissimmaler mateals.Disclaimer; "I am just an a$$hole welder, don't take it personally ."
Reply:If you have to do it, you can buy explosion welded transition plates: Al one side, steel the other (and for many other combinations of material, too)Or braze with appropriate fillerI have seen brazing fillers sold as 'magic' weld filler for this (usually seems to be the standard zinc with flux used for soft solderint aluminum), but it is NOT welding. Key: if you can do it with a propane torch, it is a soft solder blend.Re: "Keystone wheels from the 80's that have the inner hub (cast aluminum) welded to the outer steel rim by obvious welded fillets." What happens there is that a steel tab, or spine is cast into the aluminum, machined, then welded (the steel) to the steel rim. Most ornamental iron suppliers (King,etc.) offer aluminum castings with"weld tabs". These are not as neat and hidden as your on the rims, but it is the same idea.Just my  opinion, not from a book, just from the road.Howes Welding Inc.www.howesweldinginc.com
Reply:Yes you can weld steel to aluminium, but it is a complicated method.You need to use an intermedaite piece between the 2 pieces which can be welded for both materials, in our case you may use Nickel intermediate piece.Don't forget this method is an expensive one and need a qualified welder to complete the job.Good luck.Katani.
Reply:hi, just wanted to say that i successfully welded 40mm x 25mm x 1.0mm aluminium box tubing  to 40mm x 25mm x 1.2mm steel box tubing using a DC inverter MIG machine set at around 18 - 19 volts and around 90 - 100 amps. i was using 0.9mm gas-less, flux cored mild steel wire.the weld, once cleaned, looked fused and well bonded. there was a definite distinction between the two metals but a genuine bonding or fusing had happened. this job is only a fence gate but the frame was made of aluminium horizontals and steel verticals, it is strong and sturdy. i found that i concentrated my arc on the aluminium and then jumped to the steel to lay my first deposit. i then moved back to the aluminium and deposited the molten steel onto the aluminium. once weld pool was established i used a "stop, start" technique to lay the weld, fusion was neat and strong.i'm a boilermaker/ first class welder with 20+ yrs in the trade, 20/20 vision and a steady hand. having successfully welded such thin materials, i would feel confident to attempt this technique up to 5mm thick. hope this helps.P.S. out of the eight welds of 40mm length preformed, 4 of them blew through the aluminium as i was too slow with the stop, start. but the holes filled up well and i was able to grind back clean with successful welds produced. 4 of the welds were preformed perfectly with a nice bead and appearance achieved straight away.
Reply:a picture is worth a thousand words seeing is believingidealarc 250/250 ac-dc tigidealarc 250/250 ac-dc tig #2 used for sticklincoln sp100hh125dual arbor grinder polisher30 yrs of hand tools52 pitch blocks 6p-26prake gauge -pitch gaugeG&D prop repair 918-207-6938Hulbert,okla 74441
Reply:Hey dave4mel,Your post is really crap. To come here & tell others you successfully "welded" aluminum & steel is quite disingenuous. Aluminum & steel CANNOT be fused using MIG!!!!!!!!!!!!!!  WELDING IS THE "FUSION" OF METALS TOGETHER!!!!!!!! Now, if some "garage hobby" nube reads your post & decided to weld aluminum to his trailer structurally & goes down the road, what in the he11 do you think would happen??????? Duuuuuuhhhhhhh!DennyComplete Welding/Machine/Fab. ShopMobile UnitFinally retired*Moderator*"A man's word is his honor...without honor there is nothing.""Words are like bullets.... Once they leave your muzzle, you cannot get them back."
Reply:I would like to know why a 4+ year old thread was brought back to life anyway..With ALL bad info to boot!  And if it is possible...Well it's IMPOSSIBLE.....Post some pics.We'd all love to see them.......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:Pics? Stainless keg to aluminum tube:
Reply:Epoxy?3M 5200 ?
Reply:Originally Posted by VPTPics? Stainless keg to aluminum tube:
Reply:No, thats filler using TIG.  See white haz on aluminum side.
Reply:What kind of filler was used? If that thing ever fell over I bet the weld would snap :\
Reply:Originally Posted by justinTWhat kind of filler was used? If that thing ever fell over I bet the weld would snap :\
Reply:yes I agree: NOTHING LIKE THIS SHOULD EVER BE DONE TO ANYTHING BEARING ANY WEIGHT, HAS FATIGUE, OR IS INVOLVED IN ANY KIND OF SAFETY.The MOST anything like this should be attempted for is testing purposes or for small yard art. It is welded yes but the weld will never be stronger then a pencil.
Reply:Originally Posted by VPTyes I agree: NOTHING LIKE THIS SHOULD EVER BE DONE TO ANYTHING BEARING ANY WEIGHT, HAS FATIGUE, OR IS INVOLVED IN ANY KIND OF SAFETY.The MOST anything like this should be attempted for is testing purposes or for small yard art. It is welded yes but the weld will never be stronger then a pencil.
Reply:Originally Posted by dave4melhi, just wanted to say that i successfully welded 40mm x 25mm x 1.0mm aluminium box tubing  to 40mm x 25mm x 1.2mm steel box tubing using a DC inverter MIG machine set at around 18 - 19 volts and around 90 - 100 amps. i was using 0.9mm gas-less, flux cored mild steel wire.the weld, once cleaned, looked fused and well bonded. there was a definite distinction between the two metals but a genuine bonding or fusing had happened. this job is only a fence gate but the frame was made of aluminium horizontals and steel verticals, it is strong and sturdy. i found that i concentrated my arc on the aluminium and then jumped to the steel to lay my first deposit. i then moved back to the aluminium and deposited the molten steel onto the aluminium. once weld pool was established i used a "stop, start" technique to lay the weld, fusion was neat and strong.i'm a boilermaker/ first class welder with 20+ yrs in the trade, 20/20 vision and a steady hand. having successfully welded such thin materials, i would feel confident to attempt this technique up to 5mm thick. hope this helps.P.S. out of the eight welds of 40mm length preformed, 4 of them blew through the aluminium as i was too slow with the stop, start. but the holes filled up well and i was able to grind back clean with successful welds produced. 4 of the welds were preformed perfectly with a nice bead and appearance achieved straight away.
Reply:Originally Posted by shovelonDepends on your definition of a weld.A turd will stick to a fence, but it does not mean it's welded.
Reply:When you "weld" aluminum to steel using mig or tig or stick, you are basically just casting one metal around the other. This could be strong cause they could "hook" into each other. Why? I guess I have never come across a reason to attempt this since anything I make needs to stay together.Millermatic 252Lincoln 175 plusTA 185tswTA 161stlhypertherm pmax 45Victor torchHenrob torchAn S10 for each day of the week
Reply:I wouldn't be so quick to hammer someone who claims it can be done.  People once said that electric arc welding couldn't be done.  With the right combination of heat and pressure, anything can happen.  We can now make synthetic diamonds in labs, something that only the earth could do over millions of years.We know dissimilar metals can be brazed.  I don't want to get into the chemistry of it (mostly because I CAN'T) but brazing uses capillary action rather than fusion and the tensile strength of bronze filler, if done properly, is surprisingly high (maybe 40-50,000 psi?).   I know AWS categorizes braze-welding (non-capillary action) differently from brazing, but it is probably even stronger since it involves some fusion.Both metals share the similarity of being electrically conductive so they could be heated with a TIG arc to do the brazing. (I have TIG welded brass after some told me it couldn't be done).    It would take very careful heat application, but at some point, the optimum temp between the two could be reached just like using an OF-torch.  I'm not sure what filler should be used, but some metal that will bond without causing a galvanic reaction/corrosion obviously.I wonder if, instead of a bronze brazing rod coated in flux, if you could substitute shielding gas and use bronze wire in your MIG wire-feeder to join Aluminum and steel?  Sort of an automatic brazer?  Can you get spools of bronze wire?  Maybe this automatic-brazer already exists, does it?If it were me, I'd find a way to weld a bracket onto both the aluminum and steel parts and bolt them together.  It will be quicker and stronger in the end.Lincoln AC225 & MigPak 140, Lincoln Magnum SpoolGun, Miller Spectrum 375-X Plasma, Syncrowave 200 TIG, Millermatic 252 MIG, Miller Digital Elite, General 7x12" horiz/vert bandsaw, 3' box/pan brake, 20 ton press, milling machine, 12x28 lathe, etc.
Reply:What you want is a company like Dynamic Materials Corp. Probably can weld just about anything to anything else. World leader in the field. One of their several divisions. Yep, they do use explosives.http://www.dynamicmaterials.com/HomeSeen a bunch of their multiplate stuff on jobs I did. German's love it, their things like power plants are super engineered. Used a lot in the process type industries where they want some exotic / expensive stuff inside a tank and the more common stuff outside.Was a great investment, trades under the symbol BOOM, I made a few bucks on it.Some great films around on some of their techniques. If they refuse to do it, it can't be done.
Reply:Sructural epoxy.  3M Scotch-Weld DP-420 or DP-110.Jack OlsenMy garage website
Reply:Well it can be done, but it's expensive metod. Fronius invented CMT (cold metal transfer) and you can weld steel and aluminium (alu side is welded and steel side is brazed).http://www.youtube.com/user/FroniusW...17/B80IWBpjvQc
Reply:This is all very interesting yes but welding steel to aluminum is NOT what anyone here will be doing in their shop or backyard anytime soon..lets be real here OK?It is a very complicated method and very pricey to boot so forget trying to figure out ways to do it because for us that weld everyday for a living or for hobby stuff it just 'aint gonna happen..Not today not tomorrow not next year.Got that now?IT DON"T WORK with standard everyday welding equipment and consumables and that's the bottom line....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 don't know the procedure, but truck body manufacturers have welded steel hinge plates to aluminum tailgate weldments for years. have not seen any at shop for repairs. montone and summit brands come to mind.
Reply:Good video on explosion welding.
Reply:Here is a description of Cold Metal Transfer:. Seems like way beyond what the average person can achieve in a shed:http://www.fronius.com/cps/rde/xchg/...9_ENG_HTML.htmLast edited by Llundberg; 09-26-2011 at 07:23 AM.