@noddyBrian, Thanks for the continued support. We will keep trying to improve the weld as we would like it to be cosmetic; still a long way to go :) but at least we understand the load and failure parameters now. I like the idea of turning the part as we will be trying to do a lot of these as quickl...

Hi Everyone, Thanks for everyone’s help on this! Today we cleaned the part with a Stainless S. wire brush, heated up the casting, and used 5356 filler. Put a second pass on it and made sure we had good penetration. Test result was the same 4.26ft with 160lbs, however, this time the pipe broke, actua...

Hi Everyone,

Thanks for all the feedback it's really appreciated.

We will do our best to have the shop take everyone's suggestions into action moving forward.

I'll post some more photos in the coming days.

here is a photo of our part joint.

@rake,

Thanks for the suggestions. If Welded correctly, do you have Any idea what kind of load this weld should be able to withstand?

Thanks again.

Here are some more photos of the broken weld.

Hi Everyone, We are trying to weld a sand casting and an AL pipe but the strength of the weld is not that great. The weld keeps breaking. Sand casting is A356.0 Al Tube 6061. 3mm thick parts are welded, anodized then powder coated Part will be used in low temp environment; salt water The weld is bre...