Quote:
Originally Posted by TrentePieds
It is not true that anyone can learn to do a decent weld. But recognizing that, I would think that if you really mean to do what you say you wish to do, and do it in a metal boat, you should learn, if you don't know how already, to do a decent weld. In my opinion, tho' I've only tried my hand at it a few times, ally welding is easier than steel welding. And I would think that welding supplies, including the gas, are available in even the most remote corners of the inhabited world these days.
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You likely are referring to TIG welding. There are many different welding processes. For production
aluminum welding (higher deposition) it is common to see MIG done via a spool gun (the filler metal spool is in the gun you hold, as opposed to the wire feeder box with a set of rollers that "pushes" it through the hose to the gun). For lower deposition and more critical/fine/precise work TIG welding is pretty common - and likely the most common overall for Aluminum welding in general.
However - you can most certainly stick weld (GMAW) aluminum - with no gas, just a flux coated rod. For production it isn't a viable process for many reasons, however for
repairs and lighter/non-routine fabrication it is a good process to have.
Considering the discussion is on boats, the following might be a bit far off topic/out of the realm of possibility, however... If you have a home shop and are setting up for welding my number 1 recommendation is to acquire an old (like earlier than 1980) transformer stick welder with infinite
current adjustment (not a switch to preset amperages) that does AC and DC. They weigh a ton and take a lot of juice, but if the world blew up there would be two things left - cockroaches and tombstone welders. Options include Lincoln Idealarc 250 AC/DC's and Miller Dialarcs. Not only are they extremely robust machines, you can not substitute the smooth arcs these produce - its because of the mass of the transformers and the reactor chokes. Once you have a big old transformer welder then look at smaller, more efficient
inverter machines. The small machines are convenient - they just won't last like a big old transformer machine. So if the
inverter machine goes down you always have the transformer machine there to keep going. That and if you have something heavy to weld you would have to have a heck of an inverter to do it, whereas a transformer machine would handle it like a walk in the park.
Back to aluminum welding - aluminum takes a lot more
current than the equivalent
steel welding (speaking of stick welding - rod diameter and material thickness). For what in steel might take a 3/32" 6011 rod at 80 amps you might need 120-130 amps aluminum. The saying "grab a handle and hold on" comes to mind - aluminum rods burn very fast.
For a good universal rod for aluminum - check out Crown Alloys Royal 300. If you've never stick welded aluminum - and even if you have - give these a shot. They are surprisingly forgiving, easy slag
removal, and produce ductile welds. As with any welding - practice before you go to your actual work and once you learn your machine make some detailed notes for later reference. If you have a
repair that won't lend itself to much practice then the notes you have can give you a better leg up on "getting it right the first time".
If you have good AC power* on your boat you can weld up to about 150 amps on 120v, so long as you do have good AC
power and amperage to supply the machine under load (that is always a concern - even in garages as the 120v circuit likely has other things on it, so if you have 15a available but lights and a couple room circuits are also on the same breaker you don't have 15a for the welder = voltage problems). If you have 240v you can have much better
electrical performance - the machine will draw roughly 1/2 the amps at 240v than 120v so voltage drop becomes much less of a concern increasing the voltage stability.
*Another important note is inverter welders constitute "sensitive electronics". The
computers in them can not handle dirty/high THD
power. "Clean power" is generally considered less than 5% THD. True sine wave power inverters largely meet this figure. However, lots of rotary generators do not. Inverter generators (think
Honda EU2200i, EU3000i, etc) typically do supply "clean power" because they use an inverter to output the AC power - the
alternator is not what is supplying the power output directly. However, you need a big
generator to weld off of. Same with an inverter - it isn't just the inverter, you need the power behind it in the form of
batteries and C (discharge ability). If you don't have the power behind the power source when you strike an
arc welding the voltage
tanks and messes up your weld (same thing that happens in the garage power example with other devices on the same circuit - the power to the welder tanks). This drop in voltage messing up your welding is probably the number 1 beginner challenge that only goes to deter the newbies and make their
learning very difficult. Start with good power and the rest will fall in to place a lot easier. And ensure you have good power where ever you end up trying to weld. That should be
rule number 1 and the first line of troubleshooting poor
arc performance.
"Suitcase welders" are common in today's day in age of welding gear. They are small and compact, you can throw them over your shoulder with a strap like a briefcase. My portable machine is an Everlast PowerArc 210STL. It works fine - it has a lot of features on it for stick welding (adjustable arc force, adjustable hot start, VRD, and anti-stick), but also is a decent DC-only TIG machine (note that Aluminum TIG requires AC, you can try DC but the results will be terrible - if you are wanting TIG for Aluminum you really need to jump right off the deep end and get a machine that will do AC TIG = usually much more expensive). Esab, Fronius, HTP also make higher quality small suitcase welders (Fronius might lead - they are pricey but very nice). There are a lot of manufacturers out of
Europe that I'd put higher on the quality list, US made like Miller and Lincoln are good. Everlast is Asia/pacific and overall not considered a "good" brand, but they do have a 5 year warranty and their
price point is really good for what you get.
Something to think about for
repairs under-way - with a small suitcase DC stick welder you can weld any metal on your boat - aluminum and steel generally (stainless or carbon) - just pick rods for what you want to weld. The smaller the rods the lower the amperage/easier they are to run. That ability to weld on-the-go might give you a giant leg up on reducing the stress of managing a broken boat. Of course, if you end up with a problem below the
water line that is no place for an on-the-go
repair as you need to get the boat out of the
water. I would think a marina that could get the boat out of the water would have the ability to weld, but ya never know.