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 breaking when we place 160lbs at 3ft out from the weld.
Question:
1-What is the best result we can expect from our weld? 600lbs or greater?
2- How does our weld look?
Solutions for improvement
We are going to change our filler to 4145, and pre heat the parts to see if we can improve the weld strength.
Any help or info would be great as we are not sure if the shop we are using really knows what we should expect from the weld strength.