Can anyone provide tips/tricks that I should be aware of before I consider this route.

I'm looking at welding several parts together then machining out the final part.

I'd like to have the final part anodized. ((Or another protected method))

The parts are made out of 6061 aluminum, is there a certain wire I should be using?

Thanks for the help.

6061 anodizes OK (not all that great), the weld material anodizes well, but the heat affected zone does not. There's nothing you can really do about it - not even annealing seems to work - you can always spot the welded areas.

The 5000 series stuff and the weld anodizes well, but not 6061.

Are you using TIG or MIG (to answer the wire question)? Since you say wire, I assume you are migging - use ER-4043. Use pure Argon - not a mix for your aluminum Mig. Push the weld puddle with the gun at about 30 degrees to the work and good luck on any butt joints...high heat and move quick. Start on a sacrificial piece adjacent to the work to minimize the cold start problem.

Powder coating or Irridite (gold finish) coatings work well on aluminum weldments.

Scott

My plan was to take a piece of c-channel and weld laminents to the 2 sides.

Then I was going to mill down the welds and surface everything.

Really don't want to make a channel out of a solid bar if I can help it.

Mig or Tig on the welding. I have a buddy that is going to do it for me.

Hoping that the finished part will be a consistant shade of black.

Is there another coating option that might fit my project better?

A cold dip? Powder coating etc?

I would probably powder coat the part unless there are a lot of intricate features that would require masking. It's quick, tough, attractive and affordable.

Scott

I'll be happy to anodize it for you.

Sent you a PM.

How did your parts turn out, Deviant???

Scott

My plan was to take a piece of c-channel and weld laminents to the 2 sides.

Then I was going to mill down the welds and surface everything.

Really don't want to make a channel out of a solid bar if I can help it.

Mig or Tig on the welding. I have a buddy that is going to do it for me.

Hoping that the finished part will be a consistant shade of black.

Is there another coating option that might fit my project better?

A cold dip? Powder coating etc?


Before going ahead with this approach I think you should consider the distortion you are likely to get. Your welding will introduce some and then your machining will relieve stresses unevenly and you will get more distortion. One way to solve this would be to take every back close to 0 temper, weld, anneal and then retemper back to T6 or so before machining. Machining out of a solid bar might be a better option after all but this will also result in distortion unless you balance the amount of material removed on different sides of the bar.

I haven't made the parts yet.

Just started a new job, so that has been my focus.

As for machining the parts, it's not really an option due to the size.

Also, the distortion from heat should be minimal.

Hopefully, when the new job transition slows down tyhe project will get picked back up.

MBG - do you do anodizing?

Scott