Not sure how come folk struggle for penetration with the TIG on aluminium. Give it an extra burst of pedal and push some filler through to the back-side. It's easy enough to put twice as much weld on the back as what's on the front. Prettier with a back-purge too if you can get in there.
Repaired an exploded, TIG welded fuel tank from a dragster recently and whoever welded it had started with the material cold, no preheat on 1/8th material. The result was virtually no penetration and a hard weld where the surrounding material had quenched it but further round, as the heat soaked in, the penetration was much better and the weld more compliant. The tank was pressurised to push fuel uphill but the pressurisation went wrong and blew the end of the tank out with a failure beginning at the origin of the weld. Half the battle is understanding the material.
Will
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Here to learn.
William Pointer
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