The engine of your Simson or lawnmower has broken? You cannot buy the damaged part because it is no longer manufactured? Before you think desperately that that's it and the device can only be stamped in, here's the reassuring message: the whole thing can be repaired - and the magic word is "aluminum welding".We have compiled Eric's most helpful tips and tricks for you:
- Preparation is half the battle
- So you avoid that it burns
- Think good handling
- So you can weld quickly
- It depends on the nozzle size
- Choose the correct amperage
- Finally, the post-processing
- Addition: What equipment does Erik actually use?
1. Preparation is half the battle
So you shouldn't start welding right away, but first prepare yourself well. Prepare everything you will need and above all: First clean the part to be welded thoroughly.
You can heat the material with a hot air dryer, for example, to remove paint and dirt. You can use a stainless steel wire brush for cleaning.
For pre-cleaning, material can also be blasted with stainless steel balls so that the surface is nicely compacted. Erik follows this approach, for example, in the episode "Weld on the Simson motor housing".
In the last step, use acetone and clean the area to be welded again properly with a simple cloth.
Why acetone? You will find out in the next tip.
Thorough cleaning is part of good preparation
2. So you avoid that it burns
It could start burning when welding, but it shouldn't.
To avoid this, you should definitely use acetone when cleaning and not thinner. Acetone evaporates quickly, but a dilution could accumulate in small pores of the material. This can increase the risk of fire when welding. So take acetone and you're on the safe side.
For a good end result, you shouldn't ignore the dirt that can still come out of the material during welding.
So put a stainless steel brush close at hand, interrupt the welding process when you see dirt and remove it from the weld with the stainless steel wire brush.
Erik occasionally cleans the weld with the stainless steel wire brush
3. Think good handling
For welding itself, it is important to make handling as pleasant as possible and to be able to work quickly.
Therefore, lay the hose package of the welding torch on your lap for better handling. Especially when water cooling is included, the whole thing is a bit more difficult. So you don't have the weight of the hose on your wrist during welding and the torch is easier to use.
The right material thickness is also crucial for speedy work.
Especially with repair welding - as we see some in this season - a lot of material has to be applied during welding. We therefore recommend using a not too thin aluminum wire for stapling. Erik also prefers to use a slightly thicker wire (e.g. 3.2mm ALSI 5), as can be seen in the following "Simson engine cover repair weld". This makes welding faster and easier.
Work with the right filler metal
4. So you can weld quickly
Now you already know how to handle the hose package and the material thickness so that everything works well during welding. But of course you can keep more in mind to get to the desired result quickly.
For example, if something has broken off in the part to be repaired, work your way up from the lowest point. So you can build up the material nicely evenly.
And because "quick and even" is exactly what we want when welding, here's another tip: don't be too timid, but press the aluminum wire into the weld pool properly. You will see how good the welding work is then.
Also keep in mind that grinding is still required after welding. Therefore do not save on the material, but always weld a little more. So you have a good buffer later when grinding away and everything remains nice and stable.
Speaking of stability: If you also have the option of welding something from both the front and the back, then use this option. Erik points this out in the following "Repair welding on the lawn mower". He then welds the lid from both sides, which can make the whole thing 100% tight and stable again. So don't miss out on such an opportunity if you want to work cleanly.
Erik also welded the lid from the inside
5. It depends on the nozzle size
As Erik explains in the following "Welding on the fan wheel from the Simson blower motor", there are nozzles of different sizes for burners.
In this case, it is quite narrow between the blades of the fan wheel. In such cases, we recommend that you use a smaller nozzle so that you have better freedom of movement when welding. The right nozzle size will help you add the filler material well and see the weld pool. So you can build up the material even in narrow areas.
Don't forget to increase the amount of gas. This is because less gas flows through the smaller opening of the nozzle. For example, like Erik, you could increase it from 8 to 10 liters / minute.
So remember: Use a small nozzle to access tight welding work.
Use a smaller nozzle if you have less space
6. Choose the correct amperage
When welding, it is important to choose the right amperage. Depending on how thin or thick the part to be welded is, the amperage should also be higher or lower.
But it is also no problem to start with a certain number of amperes and then to regulate the strength during the welding process. For example, if you notice that the workpiece is getting too warm and the seam is starting to sink in, then adjust the current down by 20 to 30 amps before continuing to weld.
However, if you can determine from the start that the sheet thickness is very low, then set the starting current lower from the start.
Erik sets the welding machine to 160 amps, for example, in the "Welding the DKW gear cover" sequence. He also uses a suitable tungsten electrode for the TIG needle and works with a gas flow of 8 liters / minute.
Erik did not have to regulate the number of amps in our video and was able to maintain the set amps throughout the welding process.
"Choose the right amperage when welding"7. Finally, the post-processing
The last and no less important step in welding is post-processing. It is important that you bring the necessary finishing touches to the material so that the repaired area again corresponds to the original look. The good thing about aluminum: It is relatively soft, which means that it can be quickly sanded away.
During the grinding process, make sure that all welding points are sanded down. However, since the weld seam creates the necessary hold when welding aluminum, it should not be completely sanded. In the episode "Repairing the Simson Engine Side Cover" you can see how Erik grinds the weld.
Be it a hand file, polishing disc, angle grinder, etc. - there are various options available for post-processing. Choose the variant that suits you best, so that you can best bring the repaired part back to its original shape when grinding.
Finally, you have the option of using a heat protection spray. Erik used this for the gear cover, for example.
Et voilà, it is no longer noticeable that something had to be repaired at all.
Post-processing is the last step
As you can see, thanks to the aluminum welding process, the new motto is: “Repair and don't throw away!”. We hope that the tips and tricks from Eric "Aluminum spoon" and we will help you with your own welding work with aluminum. For more information, drop by the current season of “All about weld” and feel free to leave us a comment there.
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