Anything special to TIG weld aluminized steel?

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I am going to be doing intercooler pipes out of aluminum mild steel - anything I need to know when joining to pipes together?  TIG welder using 2% thoriated I have straight argon as well as Argon w/ CO2.
Reply:what do you mean exactly by aluminum mild steel?aluminum coated?tell us more.....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:Save the Ar/CO2 for mig welding on aluminized.  If you're going to go TIG, use straight argon, or a 75Ar/25Helium mix.  Dont use the 75He/25Ar you would use on aluminum.  Careful not to overheat the weld area, you'll compromise the aluminization and that can affect the corrosion resistance, critical for your intercooler application.I r 2 a perfessional
Reply:Always hated aluminized sheet metal- we can't solder it. When they would send us heavy sheet for commercial ductwork, we always ground a bit of the aluminize off, and we flux core welded it with mig. Is there a brazing you could do to make the connections?? Or, I'd say at least sand off the aluminize.
Reply:So to clarify - I want to use the straight argon on the TIG - what kind of filler metal?  Mild steel (aluminized) will require a filler right?I have some 309-SS filler and also some other rods I think they are like E70 or something like that.
Reply:You really don't want to have to TIG aluminized tubing.  If you must - grind the aluminizing off where you're going to weld and you'll be left with mild steel.  The aluminizing will do nasty stuff if you don't grind it off.  It'll probably pop and sputter and mess up your tungsten in a hurry...  Paint over your welds when you're done to keep them from rusting.Ironically, I came in here to check on an ebay item - which I missed typing this response - doh! - and was just out in the shop bead blasting the aluminizing off some exhaust pipe to TIG weld it...You should get some aluminum tubing for that intercooler!  Or at least mild steel as opposed to aluminized exhaust tubing...  Wish I knew of a mandrel tube bending shop to recommend - wait - I happen to own one!
Reply:Originally Posted by PanozengYou really don't want to have to TIG aluminized tubing.  If you must - grind the aluminizing off where you're going to weld and you'll be left with mild steel.  The aluminizing will do nasty stuff if you don't grind it off.  It'll probably pop and sputter and mess up your tungsten in a hurry...  Paint over your welds when you're done to keep them from rusting.Ironically, I came in here to check on an ebay item - which I missed typing this response - doh! - and was just out in the shop bead blasting the aluminizing off some exhaust pipe to TIG weld it...You should get some aluminum tubing for that intercooler!  Or at least mild steel as opposed to aluminized exhaust tubing...  Wish I knew of a mandrel tube bending shop to recommend - wait - I happen to own one!
Reply:I do some motorcycle Exhausts and ocassionally have to use some aluminized tubing. I bevel the edge and weld as normal using argon. The aluminizing that gets in the weld seems to float on top of the puddle. Doesnt do any thing strange though. Just figured if I can gas weld it I should be able to tig it. I get penetration at the joint and some blackening of the alum. near the weld.Havent broken any welds yet.
Reply:Originally Posted by PanozengYou really don't want to have to TIG aluminized tubing.  If you must - grind the aluminizing off where you're going to weld and you'll be left with mild steel.  The aluminizing will do nasty stuff if you don't grind it off.  It'll probably pop and sputter and mess up your tungsten in a hurry...  Paint over your welds when you're done to keep them from rusting.Ironically, I came in here to check on an ebay item - which I missed typing this response - doh! - and was just out in the shop bead blasting the aluminizing off some exhaust pipe to TIG weld it...You should get some aluminum tubing for that intercooler!  Or at least mild steel as opposed to aluminized exhaust tubing...  Wish I knew of a mandrel tube bending shop to recommend - wait - I happen to own one!
Reply:Oops - I didn't mean for this to turn into an ad...  Sorry mods!
Reply:I leave the aluminum on and TIG with 70S2 or 70S6.  The aluminum getters impurities in the weld, so leaving it on actually helps make the weld better.I r 2 a perfessional