On Tuesday, November 24, 2015 at 1:29:25 PM UTC-5, Tim Wescott wrote:
On Tue, 24 Nov 2015 07:08:58 -0800, ggherold wrote:

On Saturday, November 21, 2015 at 6:50:14 PM UTC-5, Tim Wescott wrote:
This is probably going to stay on my wish list for a good long time,
but I've been lusting after TIG welding capabilities for a while now.

Nearly all the projects that I have in mind at the momet involve
welding .03" to .06" aluminum sheet to itself and to 1/8" or 3/16"
bosses, so it looks like this thing is heavy-duty enough.

Knowing next to nothing about welding, Can you solder the aluminum
pieces together? Or do you need more strength?

I've tried soldering without a lot of success. I've also tried aluminum
brazing, which rapidly turned into half-assed aluminum welding, and then
a puddle on my bench.

I suppose I should try epoxy, but it's for a model airplane muffler and I
have visions of the thing just falling apart in the air.

Did you have the right flux? (La-co Aluminum flux paste)
I haven't done a lot but I soldered Al pieces to circuit board and
pieces of copper wire to aluminum foil. (like right off the roll in the kitchen)
I've never tried it for joining Al bits together, but I bet I could do it.

I don't know about mufflers, how hot do those things get?
There are epoxies that claim 500 F. That seem cheaper than a
new welder.. unless you mostly are looking for an excuse to buy one.

George H.

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Tim Wescott
Wescott Design Services
http://www.wescottdesign.com