Welding 6061 Aluminum Mast Section -- The Welding Forum

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Subject: Welding 6061 Aluminum Mast Section

Author:
Peter Medway

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Date Posted: 04:23:46 11/22/03 Sat

I have an aluminum mast section which is used on a trimaran
sailboat as a crossbeam to join the floats on each side to the main hull. The forward crossbeam has developed a crack
in it from the bending stresses. Normally a mast section like this which is basically elliptical is used as a vertical mast.

This crossbeam has a cavity in it approximately 2" x 2.2".

I have done some research and generally understand that in
welding this type of aluminum strength will be lost. So, even if this crossbeam is welded, the strength of the beam must be made up in some other fashion.

There seem to be two approaches:

The first would be to fit a sleeve of aluminum, possibly
pipe, tightly into the cavity and then weld.

Second, weld the beam first, trying to get a "clean weld" in the interior of the beam putting some temporary material there. With a clean weld in the interior a plastic plumbing
pipe coud be inserted and then into that some stronger material such as galvanized steel pipe. This would eliminate the corrosion problem between steel and aluminum and add the necessary strength.

I would appreciate any suggestions as to how to handle this
problem. I am not a welder and will be hiring someone else to do this.

Peter

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Replies:

Subject	Author	Date
Re: Welding 6061 Aluminum Mast Section	Brainfarth	14:07:19 11/28/03 Fri