Welding an unknown aluminum alloy

[awol]

I am providing a repair to an aluminum impact gun housing to replace stripped threads. The OEM of the impact gun will not reveal the base aluminum cast material (not even the alloy series). I can select the aluminum plug material and the filler rod. I will perform post weld testing to verify the welded plug is secure. If the welded plug repair passed the tensile testing, shouldn't this qualify the weld integrity? What would be a safe assumption for the aluminum casting material? 5052?

 

[unclesyd]

I have never recommended welding on any tool, air tools being close to the top of the list. The reason is the same as you state, what is the material of construction. These housings are either die casting or injection molded aluminum alloys and some being virtually non weldable, while others can be welded. We had the capability of analyzing the material and still didn’t weld repair.

If it is necessity I would try 4043 Al rod using a welder well versed in aluminum welding. If there is any problem during the attempt get a new housing. You will have to have a very clean surface for welding or you are going to have porosity.

Is there no way to repair the thread mechanically, like a bushing?