The Ford Barn

Tom Wesenberg · 03-03-2013, 11:16 AM

I don't recall seeing spot welded aluminum, but was wondering if it can be done? It would work nice to build a lightweight speedster.

James Rogers · 03-03-2013, 11:52 AM

Quote:

Originally Posted by Tom Wesenberg

I don't recall seeing spot welded aluminum, but was wondering if it can be done? It would work nice to build a lightweight speedster.

It can just like steel panels but, it would work best for a hobbiest, to use a mig welder and an aluminum gun. You could use a high frequency tig but that is expensive. The aluminum gun is because the wire won't stand being pushed through the housing so you use a gun that attaches to the end of the housing and the wire roll is mounted on it with a small advance motor. Miller carries these.

MikeK · 03-03-2013, 12:48 PM

Aluminum has always had reliability problems with spot welding due to the near instantaneous formation of a thin invisible surface oxide layer that becomes imbedded in the fused weld and provides a shear layer. Simply put, they tend to snap apart in time.

GM recently solved the problem through a patented re-design of the geometry of the electrode tips. I suppose you could get an extra set of tips and try their method. Here's a press-release link from GM that explains what/ how/ why. LINK Watch the 42 second video for a close up of the tip cutting and resultant welds.

norson · 03-03-2013, 03:26 PM

Lazzi has a video showing how to spot weld aluminum with a regular pinch? spot welder. You sandwich the aluminum with strips of crs and pinch and pull the trigger as normal. the weld seems strong. The problem would be making a whole car this way. I had a Marine Corps Mity-Mite that was made that way and that was a ton of welds. A neat trick when you need it but not a construction choice I would make. Norm

hardtimes · 03-03-2013, 03:34 PM

Hey Mike,
Thanks for that! Hm, using aluminum rivets on a speedster, IMO, adds to the looks/beauty and probably less expensive that welding ?

norson · 03-03-2013, 03:46 PM

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Just saw the video from GM. bet you could make a manual dresser for a pinch? welder to match that welding face. hmmm?

Tom Wesenberg · 03-03-2013, 04:36 PM

Quote:

Originally Posted by hardtimes

Hey Mike,
Thanks for that! Hm, using aluminum rivets on a speedster, IMO, adds to the looks/beauty and probably less expensive that welding ?

I agree that rivets add to the looks of an antique speedster.

03-03-2013, 11:16 AM	#1
Tom Wesenberg Senior Member Join Date: May 2010 Location: Mpls, MN Posts: 27,582	Can Sheet Aluminum be Spot Welded? I don't recall seeing spot welded aluminum, but was wondering if it can be done? It would work nice to build a lightweight speedster.

03-03-2013, 12:48 PM	#3
MikeK Senior Member Join Date: May 2010 Location: Windy City Posts: 2,919	Re: Can Sheet Aluminum be Spot Welded? Aluminum has always had reliability problems with spot welding due to the near instantaneous formation of a thin invisible surface oxide layer that becomes imbedded in the fused weld and provides a shear layer. Simply put, they tend to snap apart in time. GM recently solved the problem through a patented re-design of the geometry of the electrode tips. I suppose you could get an extra set of tips and try their method. Here's a press-release link from GM that explains what/ how/ why. LINK Watch the 42 second video for a close up of the tip cutting and resultant welds.

03-03-2013, 03:26 PM	#4
norson Member Join Date: Aug 2010 Location: Portland, Or Posts: 50	Re: Can Sheet Aluminum be Spot Welded? Lazzi has a video showing how to spot weld aluminum with a regular pinch? spot welder. You sandwich the aluminum with strips of crs and pinch and pull the trigger as normal. the weld seems strong. The problem would be making a whole car this way. I had a Marine Corps Mity-Mite that was made that way and that was a ton of welds. A neat trick when you need it but not a construction choice I would make. Norm

03-03-2013, 03:34 PM	#5
hardtimes Senior Member Join Date: May 2010 Location: South California Posts: 6,188	Re: Can Sheet Aluminum be Spot Welded? Hey Mike, Thanks for that! Hm, using aluminum rivets on a speedster, IMO, adds to the looks/beauty and probably less expensive that welding ?

03-03-2013, 03:46 PM	#6
norson Member Join Date: Aug 2010 Location: Portland, Or Posts: 50	Re: Can Sheet Aluminum be Spot Welded? Sponsored Links (Register now to hide all advertisements) Just saw the video from GM. bet you could make a manual dresser for a pinch? welder to match that welding face. hmmm?