[Onthefield]

Anyone met this? The more i weld it the more it will crack

[Jakedaawg]

4043? Try 5356.

[Coldman]

That's a big lump of aluminium. Preheat the whole zone is a must or hot short cracking will occur. Are you doing that?

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[Poland308]

Looks like a low quality casting. You will most likely need to grind the crack all the way out full thickness. I’d also recommend stop drilling at the ends. Invest in some penetrating die. So you. Know where the crack ends.

[Onthefield]

Thank you guys! I did not preheat the welding zone and welded it. This is a bad quality of aluminum casting. I will try all things you guys introduce to me. Thanks all!

[cj737]

I might also add... weld a little then stop. Peen the weld. Don’t try to weld the entire length in a single go. You’re heating the area a lot, but not much of the entire surface, hence the hot short cracks. Weld about an inch or two, then pause. Use thinner filler, and make multiple passes would be another approach.

But the recommendations above are also spot on. Mine are just extra ideas for other tricks.