I second this stainless steel wire brush dedicated to aluminum welding onlyStation said:Hey Dan, try using a wire wheel on the area to be welded(A wire brush would take way too long) and knock the polish off of it. I am not sure about this, but I think there is some kind of coating which holds the polish. As fast as aluminum oxidates, I would think the polish would not hold for long at all without something to protect it.
You need to stailness steel brush all areas to be welded on aluminum. You can not weld oxidised aluminum well at all. You need to have reall clean fresh aluminum to get a good weld.
When welding aluminum in the past, I have brushed the aluminum a few hours before I get a chance to weld, and the clean metal that I had , had already oxidized before I got around to welding it.
For best results the brush that you use needs to be a clean stainless brush, which is dedicated mostly only to aluminum work.
My attack would be with a 5" wire wheel on the angle grinder to knock the polish and any coating off, followed up by a meticulous stainless steel hand brushing.
steve gerstner said:Hey dan, i know you like to weld from left to right but, if you lead from right to left there will be no weld soot, it is a sure thing. steve
Dirk said:How old is your aluminum wire?
After 6 months throw the shit in the trash because it oxidizes too much and can't be used.
I worked for a company that made aluminum trucks beds , and if we had to wire brush every joint before welding, it would take a week before we could weld them up.Wire brushing is good if the aluminum is dirty and oxidized , but your justing wasting time if the aluminum is clean.