RE: SER1 Thermostat housing

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It is not necessary the exact constituents that is the problem with failed
attempts at Aluminium welding. You can join virtually any Aluminium alloy to
any other.
The mistake most people make is not to prepare the parts properly, I e they
have to be clean. And I don't mean "wipe the gunge off with a damp rag"
clean.
The trick is to sand, file, blast  off the outer "skin" of Aluminium oxide
that forms on any Alu part as  soon as it comes into contact with oxygen.
This oxide layer has a melting point about 4 times higher than the base
material. You try to melt that layer in the welding process and the base
metal will likely be destroyed before You can create a decent weld puddle.

Another source of frustration with engine and gearbox parts is that they are
saturated with oil and other contaminants that prevent a decent weld.
Boiling the parts in a vinegar solution helps a bit
Tom T

-----Original Message-----
From: series1-host@xxxxxxxxx.xxx [mailto:series1-host@xxxxxxxxx.xxx]On
Behalf Of Nick Condon
Sent: June 4, 2005 5:26 AM
To: series1@xxxxxxxxx.xxx
Subject: RE: SER1 Thermostat housing


Ian,

This needs great care when dealing with early Rover aluminium. The exact
constituents of the alloy are not the same as modern materials.


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