Welding

Jason Mauldin · **Posted:** Tue Oct 21, 2003 11:14 am

Does anyone have recommendations for a shop in the RTP -> Morrisville -> Cary areas that can weld a steel flange to a piece of aluminum.

Vincent Keene · **Posted:** Tue Oct 21, 2003 1:51 pm

Unlike metals...ACK!

Carl Fisher · **Posted:** Tue Oct 21, 2003 2:38 pm

People have said good things about R&J Exhaust (off Hwy 55 in Apex) for all kinds of welding work; maybe they can help.

Otherwise I'd suggest Chris at Competition Cages in Hillsborough.

Scott Johnson · **Posted:** Tue Oct 21, 2003 3:09 pm

I don't think it's actually possible to weld a steel flange to a piece of aluminum...

Maybe braze it, but not weld it.

Scott

AndersGreen · **Posted:** Tue Oct 21, 2003 3:10 pm

Jason Mauldin wrote:

weld a steel flange to a piece of aluminum.

I'm sorry, but you can't do this.

These metals are too dissimilar to weld together. Some metals you can do this with, like welding a piece of steel to stainless steel. However, even in those cases, you need special filler rod designed for exactly this kind of alloy-making.

Here's the basic problem: the two metals have different coefficients of thermal expansion. So, when you heat them up and weld them together, that's fine. When they start cooling a second later, one of the metals will contract more quickly than the other, and will crack like crazy.

I tried this out one time, welding aluminum rod into stainless steel. Very interesting. After I had layed down about one inch worth of bead, the piece of metal started making a pinging sound. As each crack formed, it sent a shock wave through the metal and used it as a sounding board. Very neato. The cracks themselves were quite obvious to the eye.

Metal is so COOL!!!

But Jason, why don't you tell us what you're trying to do, and perhaps we can come up with other solutions.

Anders

Jason Mauldin · **Posted:** Tue Oct 21, 2003 3:37 pm

AndersGreen wrote:

Jason Mauldin wrote:

weld a steel flange to a piece of aluminum.

But Jason, why don't you tell us what you're trying to do, and perhaps we can come up with other solutions.

Anders

I have a BOV Mount, that I'm trying to mount on the side of an Intercooler. Bolts aren't really an option, although, I could potentially have a aluminum bracket made to bolt the mount to for support.

I've used JB Weld to seal the mount to the IC, but I don't want to rely on that for support. I'm guessing that the mount+BOV+hose will probably weigh about 5lbs, which will be hanging on the side of the aluminum.

Scott Johnson · **Posted:** Tue Oct 21, 2003 4:19 pm

Call around, a radiator shop (or possibly R&J) should be able to solder or braze the two parts together.

Not sure about the long term durability, but brazing, when done right, is supposed to be pretty tough.

Scott

MikeWhitney · **Joined:** Wed Aug 20, 2003 9:15 pm **Posts:** 4724

Think it's strong enough to hold 5 lbs?

My goodness, going to images.google.com and searching for "duct tape" is entertaining.

Jason Mauldin · **Posted:** Tue Oct 21, 2003 4:24 pm

Woohoo, duct tape!! Now why didn't I think of that?

Chuck Frank · **Posted:** Thu Oct 23, 2003 7:14 pm

Steel and aluminum can't be joined by welding or brazing. I'm afraid you'll need to mechanically attach the two pieces by bolts, screws, rivets, clamps, or ?

Rob Keehner · **Posted:** Thu Oct 30, 2003 10:54 am

Ya'll haven't heard of inertia welding yet have you. Can be used to fuse to parts of disimilar origin. Done by spinning one part at high speed in a chuck then placing against the other. Friction causes heat and they stick together. Come on I know somebody here has seen an aluminum piston bond to the side of a steel engine block, same principle. Eitherway this wouldn't work with your application.

PS use camoflauge duct tape, thats way cooler.

Mark Vitacco · **Posted:** Wed Dec 17, 2003 7:40 pm

See my posts on recommended shops:

SAPPS: Mechanical Blve Gardner. For alloy welding, tranks , rads,
oil colers, etc & Steel

R&J: Apex: Welding and Frab work.

Talk to one of the welders at either or both of these shops for advise on
what you are tying to do. There is a guy named Randy Overbey (?)
that teaches welding at Wake Tech, you can try to contact him at
the college and consult him as well.

I must have missed that chapter in my welding book about welding
steel to allumimun or cut class that day!

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