On 28 Aug 2003 22:00:46 GMT, onloser (Building The
Perfect Beast) wrote:

I am going to begin an aircraft project this winter and it looks like I have a
LOT of welding ahead of me. I'm curious as to the different methods, ie
brazing vs. arc, etc., and what the benefits or drawbacks of each method may
be. Is one style better? Stronger? Easier? I will be working with a buddy
who owns a machine shop and he has just about all the equipment I could ever
ask for. Given that availability of equipment, what would you welders out
there recommend or prefer?

Thanks.

Welding means to fuse two metals together by melting them, often with
the addition of a filler.

There are many ways to do that: Stick, Oxy Acetylene torch, TIG, MIG
and some kind of friction method has been developed now. Of those
mentioned, stick and O/A are by far the least expensive. Of those
two, only O/A is recommended as it's very difficult to make a
satisfactory weld on thinwall tubing using a stick welder.

Thinwall 4130 tubing was developed originally to be welded using the
O/A method with a mild steel filler rod. The people who joined the
tubes using this method were really good at it and the welds are a
marvel to look at.

Anyone with the desire and a little understanding and practice can
manage a decent weld on thinwall tubing. The best method for learning
is to take a course, like those offered by Ron Alexander in
conjunction with EAA. You learn by doing yourself under close
supervision and can see with your own eys what constitutes a good weld
and what doesn't.

Brazing hasn't been tried much for several reasons but I understand
that there are brazing rods that are easily up to the task. The only
difficulty is that the brazing process is less able to fill gaps than
welding, so the joints must necessarily be closer in tolerence.

The bottom line is O/A welding is a proven method for joining thinwall
tubing and is no more expensive than brazing so why not weld?

Corky Scott