Any aluminum welders out there?

[plumcrazzy]

I need to join a section of 1 1/4" OD aluminum round stock (6160) to a section of 1/4" aluminum plate (quality unknown). Welded tons of steel of all varieties but have very little experience with aluminum. No mig---no tig--no spool gun. All I have is an old Lincoln tombstone welder that I would almost trust with my life. I have been given a 1# box of sealed Lincoln 1/8" aluminweld 43 to join these pieces. Not too concern about weld appearance just want it to be very strong. AC? DC+?DC-? Amp settings? Any and all information would be appreciated. Thanks in advance. 

[734406pk]

I haven't used these rods in years but do remember preheating thick sections improved weld penetration into the base metal. DCEP polarity (electrode positive).
Here is the link to the Lincoln site for info:
http://www.lincolnelectric.com/assets/us/en/literature/c810.pdf
Made lots of spatter so take the necessary precautions!
Good luck! 

[Cudakiller70]

 Have only done some tig and wire feed. This may still apply, we would wipe down with acetone to remove all grease and oil then removed any oxidation with a SS wire brush or scotch pad, the name of that game was clean clean clean before welding.

[YellowThumper]

Preferably the ss brush is new and has only been used on aluminum to prevent introducing contaminants.

[Cudakiller70]

Preferably the ss brush is new and has only been used on aluminum to prevent introducing contaminants.

Yup great point, gotta keep it clean for a good weld. Wire brushes/scotch pads will transfer containments.

[734406pk]

Yup great point, gotta keep it clean for a good weld. Wire brushes/scotch pads will transfer containments.

  The aluminum oxide has a melting point of around 4500 degrees F. Aluminum alloy about 1200 deg F. +-. There is no way to weld through the corrosion if there is any, unlike E6011 on steel. You must grind down to the clean base metal for any chance of fusion with these electrodes. DCEP makes it a bit harder due to the fact of little "cleaning action" as with AC GTAW (AC TIG). Weld a test piece first to get the hang of it. Good Luck with your project!