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Welding a Cast Aluminum Cylinder Head

Testimonials

Mike,

These pics come from a new aerospace test facility that they are constructing at the University of Notre Dame. The SSF-6 is working great.

 

aluminum welding and metal repair

I am attempting to make all of these fittings air tight as they are used for pressure measurements. We can¹t have any leaks. I had very little warpage of my base metal and I think this is really going to work out very well.

 

metal fabrication and repair with muggyweld

Thank you,

 

David Hipskind
Turbomachinery Technician
The University of Notre Dame
Institute for Flow Physics and Control (FLOWPAC)
The Hessert Laboratory for Aerospace Research

 

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This is a 1997 Ford F150 aluminum cylinder head with corrosion eating right through the aluminum. The replacement cost for this part was $2200. Since there was nothing wrong with the workings of the cast aluminum head itself, Steve at Alternative Automotive wanted to save the aluminum head rather than replace it.

 

 

Note the hole is the size of a quarter. It's important to use oxyacetylene with cast aluminum parts due to the mass.

 

 

Heat the cast aluminum until the top layer starts to dimple. Then, fill the gap by building from the bottom with the Super Alloy 5.

 

 

After the welded cast aluminum head cooled, Steve finished the part with a disc sander.

 

 

Heres a shot from above to see the down into the weld with no obstruction.

 

 

This is why they are called Alternative Automotive, Steve welded the cast head in the truck and saved his customer a lot of money. The weld was made over a year ago and the truck is still running strong. Thanks Steve!

 

 

TIPS:

 

Watch our videos showing how to braze cast aluminum.

 

Note: For safety reasons, remove parts before brazing.

 

Super Alloy 5 Products

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Super Alloy 5 Starter Kit 1/16"
Super Alloy 5 Starter Kit 1/16"

Super Alloy 5 is the 600°F aluminum brazing alloy--bonds at half the melting point of aluminum ..

Super Alloy 5 Starter Kit 3/32"
Super Alloy 5 Starter Kit 3/32"

Super Alloy 5 is the 600°F aluminum brazing alloy - bonds at half the melting point of aluminum ..

Super Alloy 5 Full Kit 1/16"
Super Alloy 5 Full Kit 1/16"

Super Alloy 5 is the 600°F aluminum brazing alloy--bonds at half the melting point of aluminum ..

Super Alloy 5 Full Kit 3/32"
Super Alloy 5 Full Kit 3/32"

Super Alloy 5 is the 600°F aluminum brazing alloy--bonds at half the melting point of aluminum ..

Super Alloy 5 Replacement Flux
Super Alloy 5 Replacement Flux

1 container powder flux (shelf life 1 year) ..