I'm TIG welding a short section of 1/2" diam aluminum rod into a hole in 1/8" aluminum plate (which has already been welded to a piece of tubing). A hole through the rod will be taking a lot of force, and the weld bead will help transfer the tension side of the force to the plate. I'm having a lot of trouble getting the heat where I want it and keeping the weld bead small enough; it seems like once I get enough heat to form a pool it just wants to climb right up the side of the rod. Here's a couple photos that show the situation (force direction is from right to left):
For a while I decided to give up on welding this part and to just braze it in, which seems to work ok with HTS-2000, but I'd really prefer to not add another process if I don't have to, so I'm back to trying to weld it.
Thanks!
Mike