Using/Bending/Welding Different Grades of Aluminum

[Dyno6942]

It seems that most jon boat manufacturers use 5052 grade aluminum for their hulls. In regards to materials for jon boat mods, i.e.: sheet, tubing, angle, etc., can these grades be mixed, and if yes, what mig wire would I use to weld these different grades? I' ve been told to use the wire grade of the lowest grade part being welded. Also, does aluminum sheet (.100) have a grain direction, or can it be bent in any direction? Bends would not be greater than 90 degrees.
Thanks,
Don

 

[Ranchero50]

5052 and 6061 weld together easily enough with .035" 4043 wire. The difficulty is controlling the heat, keep the weld heavier on the thicker material, kind of like welding really thin steel sheet metal.

I've never had trouble breaking small chunks of .100 but it works better if heated first and I don't really pinch a hard crease in the sheet. You'll have to experiment with your machine.

 

[bassboy1]

I would be using 5356 for welding those alloys under most circumstances. 4043 shines in a few instances (higher heat applications, parts requiring post weld heat treating, or if I want the weld to age harden a bit), but on any boat related project like you're planning, 5356 is much preferred. Also, it will feed better than the softer 4043.

5052 can be bent with minimal radii. You can get away with a knife edge bend on up to .090, but after that, a 1x thickness radius is preferred in the .100 on up. Give the 6061 a 4x thickness radius, if bending that. Of course, these figure sheet thicknesses in the .063-.125. Thicker than that follows a whole different set of rules. There is a grain direction, and it does affect the bend, but if using the proper radius dies, it will not be an issue. Springback sometimes will vary depending on direction.

On those boat, sheet material will usually be 5052, extrusions usually 6061, maybe some 6063.