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Repair of aluminium castings?

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Andrew Tinsley	09/07/2017 17:48:23
1817 forum posts 2 photos	I have a straight break in a round section of an aluminium casting. Is repair possible without resorting to TIG welding? I do have an old US TIG machine, but the casting is around 20mm in diameter. I doubt my ability to build up weld, with an item that size. Apart from TIG and my late lamented father abilities with oxy acetylene, is there any other way of repairing the break, short of using some sort of splints to add strength? Andrew.
Neil Wyatt	09/07/2017 18:43:38
19226 forum posts 749 photos 86 articles	You could try alutite or similar.
Peter Tucker	09/07/2017 19:33:49
185 forum posts	Hi Andrew, I suggest making a new casting. Peter.
JasonB	09/07/2017 19:42:20
25215 forum posts 3105 photos 1 articles	A lot depends on what sort of loads it is likely to see, if not much load then maybe drill out each end of the break and bond in a steel dowel with something liek JBWeld
Andrew Tinsley	09/07/2017 20:31:07
1817 forum posts 2 photos	I have used aluminium eutectic material and pinning with JB weld, I am a bit dubious of either method for this particular problem. It broke in use and this makes me a bit suspicious that it is underrated, unless I have a flaw in the casting. Standing back and looking and thinking, made me realise that I could substitute the offending casting with a steel fabrication. This is perhaps my best bet as it won't break there again! Thanks everyone for your suggestions, Andrew.
D Hanna	09/07/2017 23:50:58
45 forum posts 6 photos	Neil, is that the one which is about 2.5mm dia which was being sold around the shows? My last lot was bought at Barkston Heath during the 2006 Model Nationals. Would like some more but the supplier I bought it from seems to have gone. Any leads? Great material which is far better than the zinc based one.

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