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How to Prevent 'Blowout" When Welding Thick Metal to Thin



Kevin admits even he forgets this at times, but when welding thin metal to thick, you always want to keep most of your heat on the thick piece of metal.

He has a 1/2" and a 1/8" piece of aluminum jigged up on his workbench. Kevin shows how you don't want to weld right on the joint, as you usually do when welding similar weight metals, but rather about 1/8" onto the thicker metal. Otherwise, you're just going to blow the thinner metal away.

Of course, this works with any kind of metal.

Kevin then makes some sparks, TIG welding at 170 amps, with all of the heat on the thicker piece of aluminum. Not on the joint, and not on the piece of 1/8", which was really starting to eat away, but on the 1/2" piece of metal.

Once the piece of 1/2" plate heated up, you can see how he was able to speed up his movement a bit by looking at the weld.

So that's just a little reminder for you.

Kevin is ready to clean up and get back to work, but you might want to hang around for another moment to see just how hot that aluminum he just welded really was ....

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