Hey,

Can thing sheet aluminum be welded to thicker cast aluminum? I ask because I have a set of aluminum valve covers that have no baffles, and I was just going to make a set from some thin sheet aluminum, and maybe just have a shop tack them in place for me.

Can thin sheet aluminum be welded to thicker cast aluminum? It just needs to be tacked in a couple spots to hold them in.

 

it can be done but it sounds like you're asking for (needing) someone to do it who is good with a TIG welder.

 

it will be just like welding any aluminum, the same, just don't it too hot or you will blow through the thin stuff

 

just make sure everything is really clean, and a good tig welder helps

 

It can be done assuming that both are made of weldable grades of aluminum. Flat sheet stock and castings can be made of grades that are not weldable, and weldingany aluminum makes it weaker (the reason that as bonding/glue technology gets better, aluminum gets more common in car parts/bodies)