Welding Tips and Tricks

Ok so, I have a new project at work which involves welding some 1/4" flat bar to some .050 sheet metal. I've done some practice runs but cant figure out why or how to prevent the warp.There is a chance of anodizing some I'm using 5356 filler. My settings currently very widespread but mostly 150 on freq. 80% en and somewhere in the 60-70 amp range. 1/16" 2% lanthananted tungsten with a #5 gas lens setup. I have a the weapons at my disposal ie. Copper heat sinks and clamps and I'm working on a fixture. How and what would you guys do? The pics show my first attempts and the fixture I'm working on along with the cleat and housing that are to be welded together.

Are both pieces of aluminum the same grade? Dissimilar metals expand at different rates even if the are almost the same.
Have you tried welding from one side to the other without tacking it so it has a place to stretch to?

If I was attempting this, my gut would say to start tacking in the middle of the long side of the bar and work my way to the ends. I'd probably do 5 or 7 tacks per long side and one in the middle of the short side. And I'd probably put a heavy weight on top of the bar.

Looks like the stuff I get that have been all finish machined then they come give it to me and say don't get it hot...so I tell them go try JB weld! Haha.

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Zanks process will probably work, he's the current weld porn master
If it doesnt are solid rivets an option? (Thats the airframe fitter in me talking).
What is the part used for?

Try this: Shrink the warp out after it's been welded.

Have a large soaking wet rag on hand. Warm the back of aluminium sheet where the distortion is with a gas flame, then Immediately apply the cold wet rag to the heated area. It should shrink back to less than it was previously. Repeated attempts should get it back pretty tight.

Let us know how you go.

Trev

Cool idea, Trev!

TRACKRANGER wrote:Try this: Shrink the warp out after it's been welded.

Have a large soaking wet rag on hand. Warm the back of aluminium sheet where the distortion is with a gas flame, then Immediately apply the cold wet rag to the heated area. It should shrink back to less than it was previously. Repeated attempts should get it back pretty tight.

Let us know how you go.

Trev

I do this regularly with stainless pipe. (The folk who built what I work on don't seem to own levels or squares.)

Note the metal must be quite hot; You should get a violent burst of steam when you apply the rag.

Steve S

In 1 of Tom Lipton's books there is a whole chapter on flame straightening. You may also find it on youtubve.

I've tried to weld .050 with little success in the warping department. The app. I've dealt with is Pontoon boat play-pen replacement. What I've noticed is that there is a tremendous amount of stress in the sheet stock, and the SECOND the heat hits it, it warps. Haven't found a solution yet.