[rickyv51]

Hello,
Has anyone ever had the experience of welding regular aluminum bar (flat bar, angle, or rod) to cast aluminum? What was the outcome? Any special instructions?
Thank you

[Poland308]

You may need to indicate what kind of aluminum the flat bar is.

[rickyv51]

The aluminum is common bar stock probably a 6061.

[AndersK]

I have, but to 1050, not to 60-series.
Used 4043 filler
Came out a little bubbly but not to bad. Casting was a lightning pole, clean but with some degree of porosity.
Still holding up as far as I know.

[Turbo]

I cut the bottom off of an old BMW oil pan and welded in a 6061 box with hinged baffles and extra quart capacity. I used 4043. That project was done with my Diversion 165 5 years ago, and is the primary reason I don't recommend anyone buying that machine. It held up for the 3 seasons I raced that car and as far as I know is still ok after I sold it. I had to remelt the joints a few times to get rid of the porosity and pinholes. I needed more cleaning action and higher amperage. I wasn't able to get all the pinholes out of the joint between the cast and 6061, so I smeared JB around the outside. Now that I'm older and wiser and have better equipment I could get an airtight weld no problem. I could maybe do it with that Diversion now if I had a helper with a torch to keep it hot.