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12 members (gregnbc, StateLine, catdoctor, coosabuckhunter, UA Hunter, Exhoosier, Stacey, dustymac, JD53, BrandonClark, 2 invisible),
774
guests, and
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robots. |
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Key:
Admin,
Global Mod,
Mod
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Joined: Apr 2017
Posts: 18,058 Likes: 43
Old Mossy Horns
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Old Mossy Horns
Joined: Apr 2017
Posts: 18,058 Likes: 43 |
Precision welding isn’t in my skill set, so I’m no help to the OP.
I just have sense enough to know it and not give him bad advice.
However, if this happened to me, I know a fella that could fix it. 
We’re not dead. We just smell that way. Dayum. - AC870
Yessir! I’m always gonna shoot what makes me happy and I want everyone else to do the same! If you shoot one be proud of it and don’t worry what anyone else thinks. - SJ22
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Joined: Jul 2011
Posts: 39,598
Freak of Nature
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Freak of Nature
Joined: Jul 2011
Posts: 39,598 |
Precision welding isn’t in my skill set, so I’m no help to the OP.
I just have sense enough to know it and not give him bad advice.
However, if this happened to me, I know a fella that could fix it. I'm a welder and I'm learning so much. Keep it coming. I'm involved with aluminum welding 5 days a week. All our welding is pulsed MIG. I wouldn't even attempt to repair what the OP needs to be repaired, for anyone that wasn't a friend. It's a craps shoot with cast aluminum. If the OP is dead set on having it welded, then I would recommend that he finds someone to heliarc it. Each piece would need to be properly beveled, and possibly preheated depending on how hot it gets while grinding the bevels, before welding starts. There's an art to welding aluminum, that isn't required on steel.
If my people, who are called by my name, will humble themselves and pray and seek my face and turn from their wicked ways, then will I hear from heaven and will forgive their sin and will heal their land. 2 Chronicles 7:14
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Joined: Apr 2007
Posts: 14,317 Likes: 4
Booner
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Booner
Joined: Apr 2007
Posts: 14,317 Likes: 4 |
Tig will be the only way but if it’s cast and sees any vibrations, good luck.
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Joined: Nov 2013
Posts: 4,194 Likes: 49
10 point
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10 point
Joined: Nov 2013
Posts: 4,194 Likes: 49 |
Look up belzona. We’ve put 480 disconnect handles on with this stuff repaired boats etc.. it can be sanded it’s bad stuff. Jb weld on steroids.
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Joined: Jan 2020
Posts: 798 Likes: 11
4 point
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4 point
Joined: Jan 2020
Posts: 798 Likes: 11 |
Belzona is good stuff for sure. Red hand, splash zone, etc. are good to go also but don’t hold up to vibration like belzona.
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Joined: Dec 2004
Posts: 5,777 Likes: 11
12 point
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12 point
Joined: Dec 2004
Posts: 5,777 Likes: 11 |
Hell Zip tie that thing with some heavy duty zip ties!! 😂😂
I Pledge Allegiance to the flag of the United States of America. and to the republic for which it stands, one nation under God, indivisible, with liberty and justice for all.
Some men are born brothers, Others earn it... JD
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Joined: Dec 2004
Posts: 20,179 Likes: 81
Freak of Nature
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Freak of Nature
Joined: Dec 2004
Posts: 20,179 Likes: 81 |
Clean it with a wire brush, it should be REALLY CLEAN. Aluminum is cleaned with acetone before welding, not a wire brush. I used to be really good at it but that was 30 years ago. You’re going to have to find someone who can tig weld it. MiG welding on aluminum is okay but not for fine parts. Aluminum rods for stick welding is a waste of money.
If voting made any difference, they wouldn’t let us do it.-Mark Twain
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Joined: Nov 2013
Posts: 2,780
10 point
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10 point
Joined: Nov 2013
Posts: 2,780 |
Cast aluminum is often too porous to be welded properly. Moltened together it has pretty good strength. Trying to fill a crack or anything structural in cast is asking for trouble. It really depends on the casting method. It can be done, I just don’t have good experience with it. Pre heating to molten temps will be your friend.
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Joined: Dec 2012
Posts: 4,006 Likes: 12
10 point
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10 point
Joined: Dec 2012
Posts: 4,006 Likes: 12 |
I used to TIG aluminum castings every day. We’re an aluminum foundry and, on certain jobs, were allowed by the customer to weld certain defects in certain areas of the casting. You need to know if the casting was made using one of the sand casting processes. If so, it is going to be full of trash. As the casting is heated, all of the sand, process coatings, and such that are in the porosity are goi no to float to the top, the molten area. When our guys were welding, you could see them flicking the filler rod. They were flipping the trash off as it floated to the surface. If the casting was made in China, Korea, or India, this problem will be even worse.
Last edited by Turkey; 08/26/23 09:30 PM.
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Joined: Mar 2015
Posts: 4,883 Likes: 5
12 point
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12 point
Joined: Mar 2015
Posts: 4,883 Likes: 5 |
Use the jb weld for that. By the time you take it off and have it welded you can buy a new one and it more than likely won’t hold with cast aluminum
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Joined: Oct 2009
Posts: 7,068 Likes: 50
14 point
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14 point
Joined: Oct 2009
Posts: 7,068 Likes: 50 |
I used to TIG aluminum castings every day. We’re an aluminum foundry and, on certain jobs, were allowed by the customer to weld certain defects in certain areas of the casting. You need to know if the casting was made using one of the sand casting processes. If so, it is going to be full of trash. As the casting is heated, all of the sand, process coatings, and such that are in the porosity are goi no to float to the top, the molten area. When our guys were welding, you could see them flicking the filler rod. They were flipping the trash off as it floated to the surface. If the casting was made in China, Korea, or India, this problem will be even worse. That's the key, you have to burn the impurities out and the success depends on the material.
"And the days that I keep my gratitude
Higher than my expectations
Well, I have really good days" Ray Wylie Hubbard
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Joined: Apr 2007
Posts: 14,317 Likes: 4
Booner
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Booner
Joined: Apr 2007
Posts: 14,317 Likes: 4 |
I used to TIG aluminum castings every day. We’re an aluminum foundry and, on certain jobs, were allowed by the customer to weld certain defects in certain areas of the casting. You need to know if the casting was made using one of the sand casting processes. If so, it is going to be full of trash. As the casting is heated, all of the sand, process coatings, and such that are in the porosity are goi no to float to the top, the molten area. When our guys were welding, you could see them flicking the filler rod. They were flipping the trash off as it floated to the surface. If the casting was made in China, Korea, or India, this problem will be even worse. That's the key, you have to burn the impurities out and the success depends on the material. 75/25 helium/argon is your friend when welding dirty aluminum. It’s gotten very expensive in the last year though. Doubled in price. I keep a bottle on hand but it’s hard to go back to straight argon because the 75/25 burns really clean and really hot. Less amperage is needed.
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Joined: Jul 2011
Posts: 39,598
Freak of Nature
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Freak of Nature
Joined: Jul 2011
Posts: 39,598 |
I used to TIG aluminum castings every day. We’re an aluminum foundry and, on certain jobs, were allowed by the customer to weld certain defects in certain areas of the casting. You need to know if the casting was made using one of the sand casting processes. If so, it is going to be full of trash. As the casting is heated, all of the sand, process coatings, and such that are in the porosity are goi no to float to the top, the molten area. When our guys were welding, you could see them flicking the filler rod. They were flipping the trash off as it floated to the surface. If the casting was made in China, Korea, or India, this problem will be even worse. You work at that foundry in Talladega? I'm going to contact them soon about some castings.
If my people, who are called by my name, will humble themselves and pray and seek my face and turn from their wicked ways, then will I hear from heaven and will forgive their sin and will heal their land. 2 Chronicles 7:14
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Joined: Dec 2012
Posts: 4,006 Likes: 12
10 point
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10 point
Joined: Dec 2012
Posts: 4,006 Likes: 12 |
No, sir. We’re in Sylacauga.
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Joined: Jul 2011
Posts: 39,598
Freak of Nature
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Freak of Nature
Joined: Jul 2011
Posts: 39,598 |
If my people, who are called by my name, will humble themselves and pray and seek my face and turn from their wicked ways, then will I hear from heaven and will forgive their sin and will heal their land. 2 Chronicles 7:14
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Joined: Oct 2013
Posts: 2,169
8 point
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8 point
Joined: Oct 2013
Posts: 2,169 |
Thanks for all the input. I don't know how to post pic. When I initially priced the pump online, it was giving me a range of $1600-$2000 just for the pump. My buddy checked and was finding them in the $350-$450 range. Maybe the difference between new and remanufactured, idk. Anyway, I ordered one for $355. I figured it was worth that to not wonder if the weld would hold. When the casting broke, the vibration wound up breaking the injector leak off line. That was the first indication that something was wrong but I still didn't realize there was an issue with the pump because it all ran normally. After I replaced the leak off line, it promptly broke again and the pump started leaking oil. So I really prefer to put in another pump so I don't have to wonder if the repair will hold and if it doesn't, is it going to tear something else up.
Thanks again for all the input.
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