How to tack aluminum " l l into L."

Question

Joining two 1/8" x 1/2" aluminum together to form an L shape isn't easy. I clip an 80-Amp arch welder to each piece and slowly bring the pieces together using a mechanical press. They bond well but not strong enough. This is a quick way to join steel (unsure if it's harming the welder) but aluminum is difficult. What is the correct way to join two pieces of aluminum in flash?

I'm trying to make sawhorse patterns out of aluminum sticks. Unlike steel, aluminum can't simply be bent into Zs, Ls, Vs, Ns, or Ss.

Thanks

Rich Jones · Accepted Answer

Not sure if this will work, but you might try some of the good general principles for working with alumninum:

1) wire brush very clean with stainless brushes 2) Use some shielding gas (argon).

Maybe you could build a set of jigs, and tack them together with a TIG or MIG.

Rich

Tom Martinello · Answer

I used to work in a few factories, and all we ever did was using either manual or hydraulic presses to make whatever shape we wanted with aluminum. We used to use mostly a hydraulic brake press to do shapes, but sometimes just hydraulic overhead presses.

Joe Blow · Answer

The ability to bend aluminum into shapes varies hugely with the alloy used. You can fold 3003-O1 back on itself, but 6061-T6 will crack if it is bent past 100-120 deg.

I don't know about Tibur's flash welding plan, I have a feeling it won't be very successful. So far as I know, I've never seen anything made of aluminum that was fabricated quite the way he's attempting to do it.

J.B.

How to tack aluminum " l l into L."

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