Welding aluminum to aluminized steel.
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Welding aluminum to aluminized steel. I am using a lincoln mig welder with gas and can use either solid core for steel and aluminum wire for aluminum. Whats the best approach for welding aluminum to aluminzed steel (blowoff valve to 3" aluminzed tubing).
I really do hope you're kidding.
Aluminized steel is just steel that has a coating to prevent rust (for at least a little while) and welding it is not a good idea because it offgasses and can be bad for your health...the coating also contaminates the weld and makes it weak...the heat of the weld will burn the coating off making it very easy for it to rust, and thus you generally need to prep the area you want to weld with a wire wheel or some other means of removing the coating before you even try.
That said, you cannot weld aluminum to steel, regardless of coating. You should be using aluminum tubing.
Aluminized steel is just steel that has a coating to prevent rust (for at least a little while) and welding it is not a good idea because it offgasses and can be bad for your health...the coating also contaminates the weld and makes it weak...the heat of the weld will burn the coating off making it very easy for it to rust, and thus you generally need to prep the area you want to weld with a wire wheel or some other means of removing the coating before you even try.
That said, you cannot weld aluminum to steel, regardless of coating. You should be using aluminum tubing.
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I really do hope you're kidding.
Aluminized steel is just steel that has a coating to prevent rust (for at least a little while) and welding it is not a good idea because it offgasses and can be bad for your health...the coating also contaminates the weld and makes it weak...the heat of the weld will burn the coating off making it very easy for it to rust, and thus you generally need to prep the area you want to weld with a wire wheel or some other means of removing the coating before you even try.
That said, you cannot weld aluminum to steel, regardless of coating. You should be using aluminum tubing.
Aluminized steel is just steel that has a coating to prevent rust (for at least a little while) and welding it is not a good idea because it offgasses and can be bad for your health...the coating also contaminates the weld and makes it weak...the heat of the weld will burn the coating off making it very easy for it to rust, and thus you generally need to prep the area you want to weld with a wire wheel or some other means of removing the coating before you even try.
That said, you cannot weld aluminum to steel, regardless of coating. You should be using aluminum tubing.
What about running stainless for charge pipe? Pretty much aluminum only bonds to aluminum, period? I would use aluminum but have NEVER welded aluminum before and don't really trust myself with a complete seal not knowing the material.
How hard is aluminum to weld with a mig?
Also, I can fab up a pipe for the blowoff valve out of mild steel to take place of the aluminum.
Aluminized steel *is* mild steel. It just has an aluminum coating on it, as was mentioned.
I'd weld a mild steel pipe and flange on to the aluminized tubing, and then somehow bolt or attach the BOV to that. Use silicon hose and a pair of clamps if you have to, to attach the BOV to the pipe/flange/whatever (that's what the turbo kit I have did - a steel tube, silicon hose, and then the BOV). But don't try to weld aluminum to steel.
I'd weld a mild steel pipe and flange on to the aluminized tubing, and then somehow bolt or attach the BOV to that. Use silicon hose and a pair of clamps if you have to, to attach the BOV to the pipe/flange/whatever (that's what the turbo kit I have did - a steel tube, silicon hose, and then the BOV). But don't try to weld aluminum to steel.
Last edited by Camaroholic; Jul 31, 2009 at 04:05 PM.
What brand and type of blowoff valve do you have?
Most companies offer both steel and aluminum flanges for their valves. If you can find a steel flange you can weld attach it with your mig to the aluminized piping.
Be sure to remove as much of the aluminized coating as possible before welding. It will make fore a poor weld and the fumes can harmful.
Most companies offer both steel and aluminum flanges for their valves. If you can find a steel flange you can weld attach it with your mig to the aluminized piping.
Be sure to remove as much of the aluminized coating as possible before welding. It will make fore a poor weld and the fumes can harmful.
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Aluminized steel *is* mild steel. It just has an aluminum coating on it, as was mentioned.
I'd weld a mild steel pipe and flange on to the aluminized tubing, and then somehow bolt or attach the BOV to that. Use silicon hose and a pair of clamps if you have to, to attach the BOV to the pipe/flange/whatever (that's what the turbo kit I have did - a steel tube, silicon hose, and then the BOV). But don't try to weld aluminum to steel.
I'd weld a mild steel pipe and flange on to the aluminized tubing, and then somehow bolt or attach the BOV to that. Use silicon hose and a pair of clamps if you have to, to attach the BOV to the pipe/flange/whatever (that's what the turbo kit I have did - a steel tube, silicon hose, and then the BOV). But don't try to weld aluminum to steel.
Question, why is aluminized steel so much cheaper than mild steel?
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What brand and type of blowoff valve do you have?
Most companies offer both steel and aluminum flanges for their valves. If you can find a steel flange you can weld attach it with your mig to the aluminized piping.
Be sure to remove as much of the aluminized coating as possible before welding. It will make fore a poor weld and the fumes can harmful.
Most companies offer both steel and aluminum flanges for their valves. If you can find a steel flange you can weld attach it with your mig to the aluminized piping.
Be sure to remove as much of the aluminized coating as possible before welding. It will make fore a poor weld and the fumes can harmful.
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Verdad Gallardo You might want to paint the piping when you're all done welding, to try to keep it from rusting.
Aluminized tubing is typical exhaust tubing. It is not A500 quality and will not withstand the temperatures needed in a turbo setup. If it is only for your charge tubing make it out of thin wall stainless. It will shine up nice and you can run a thinner wall to offset the weight.
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dont try and kid yourself spool guns suck aluminum is best left for a T.I.G. welder if your turbocharging something get off your wallet and do it right the first time with aluminum charge tubing and stainless exhaust tubing aluminized is for stock replacement honda accord exhausts not a turbocharged ls1
dont try and kid yourself spool guns suck aluminum is best left for a T.I.G. welder if your turbocharging something get off your wallet and do it right the first time with aluminum charge tubing and stainless exhaust tubing aluminized is for stock replacement honda accord exhausts not a turbocharged ls1
I remember trying to weld Al with a MIG and no spool gun... it took me forever to get all the bunched up wire out of my cable 
There is a way you can attatch Al to steel.... 3M panel bond adhesive PN 8115. It's good enough to hold the body onto the frame of a Corvette it'll hold your BOV on just fine.
There is a way you can attatch Al to steel.... 3M panel bond adhesive PN 8115. It's good enough to hold the body onto the frame of a Corvette it'll hold your BOV on just fine.
I remember trying to weld Al with a MIG and no spool gun... it took me forever to get all the bunched up wire out of my cable
There is a way you can attatch Al to steel.... 3M panel bond adhesive PN 8115. It's good enough to hold the body onto the frame of a Corvette it'll hold your BOV on just fine.
There is a way you can attatch Al to steel.... 3M panel bond adhesive PN 8115. It's good enough to hold the body onto the frame of a Corvette it'll hold your BOV on just fine.
TIG is by far the best for aluminum and stainless steel. It is alot more expensive but you will end up with a better looking product. I am a TIG welder for a machine shop and when a customer brings in something to be TIG welded the shop charges 95 per hour and has a 2 hour minimum.
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I remember trying to weld Al with a MIG and no spool gun... it took me forever to get all the bunched up wire out of my cable
There is a way you can attatch Al to steel.... 3M panel bond adhesive PN 8115. It's good enough to hold the body onto the frame of a Corvette it'll hold your BOV on just fine.
There is a way you can attatch Al to steel.... 3M panel bond adhesive PN 8115. It's good enough to hold the body onto the frame of a Corvette it'll hold your BOV on just fine.
I forgot about this thread. And it was a pretty stupid question, but like they all say, gotta start somewhere, lol. I did the exact same thing and it took me about 2 hours to finally get all the wire out of my feed line. I'll NEVER attempt that again!
