Hi all.

I’m hoping you can help me. I know very little about welding. We have
some .093 aluminum that has been bent into a box shape and then seam
welded. The seams are then ground smooth. On a few of these units, we have
noticed what looks like a crack beginning to form at the weld at the lip.

Further investigation has found that the welder used the wrong material to
make these welds. Apparently, he used tungsten for steel instead of
tungsten for aluminum.

These boxes hold electronic equipment and are installed in vehicles, hence,
a fair bit of vibration.

What will the ultimate repercussions of this wrong tungsten be on the final
structure of this box? Will the small cracks propagate along the weld? Is
it likely that we will see these cracks on all units? Is there anything
else I should be concerned with?

Thanks in advance for any and all replies.

Virgil

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