Quote:
Originally Posted by SuperB70
its ok to weld ( fusion) with tig without using any filler but you have to understand that by doing that the metal get poor and thats why you can get those little craters and holes. More better material, more it will happen.
Like it doesnt matter much with normal sheet metal but does matter a lot with aluminium ,stainless or titanium.
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Definitly agree that the weld is not as strong. When I was playing around with aluminum tubing scraps figuring this out I had some of the welds I had fusion welded fracture when I was "destruction testing" them to see how they strong they were.
Another thing to consider is that when you fusion weld is that the weld sinks in. If you are trying to grind the weld flush after the fact you will have a valley from the weld. Especially when TIG'ing aluminum intercooler tubing that you are going to flush for paint it is better to fill above the level of the material.