On Wed, 23 Jul 2014 22:45:56 -0500, "Terry Coombs"
wrote:

wrote:
On Wed, 23 Jul 2014 20:18:48 -0500, "Terry Coombs"
wrote:

Meanie wrote:
I plan to have someone weld 4 sections of a layout using 6061
aluminum which you can see
here.....https://www.flickr.com/photos/18223943@N06/14542109948/

This corner/section
https://www.flickr.com/photos/182239...n/photostream/
where the two pieces meet at the side, the corners touch. I cut the
other two corners for a flush cut.....
https://www.flickr.com/photos/182239...n/photostream/

Should I cut one side piece to make flush with the other for better
welding or will a good welder be able to fill that in for a secure
job?
Thanks

The first pair , you need to widen the vee a little , give the welder
somewhere to put some filler . The other pair should also touch at
the inside corner , and have about a 60° vee .
If tigging a "V" is not necessarilly required - Autogenous welding
doesn't even need filler (or much filler)

I thought that was a no-no when welding aluminum and that filler was
required . Something about the weld area being subject to cracking .
I guess it depends on the alloy, the fit, and the application - but
what would cause it to crack more from autogenous welding than from
filling a "V" with filler? Particularly if the filler is identical to
the base metal - which you want it to be if the weld is to totally
blend in. We have often used strips of the metal being welded as
filler where required You can't find the welds in the cowling for my
plane (utility grade aluminum flashing material)