How to Weld Kirksite

Welding Kirksite requires special MIG welding wire.

Welders use kirksite, an alloy of zinc and aluminum, predominantly in the production of injection molds. Kirksite is an easily machined material that makes it ideal for such things as test runs and prototypes. Welding kirksite resembles the process of welding standard aluminum. Grind the weld after it has cooled to match the surrounding metal's shape, if you wish, without damaging the weld itself.

Things You'll Need

• Rubbing alcohol
• Stainless-steel wire brush
• Zinc-aluminum-alloy welding wire
• MIG welder
• Welding clamps
• Welding helmet

Send to Phone

Brought to you by

Send to Phone

Please enter your 10 digit phone number only.

Send

A link to this article has been sent to the phone number provided.

Close

Reply HELP for help, STOP to end. Message and data rates may apply.

Instructions

1. Clean the kirksite parts being welded with rubbing alcohol and a stainless-steel wire brush. After a few moments, the rubbing alcohol will dissipate. There is no need to wipe the part.

2. Load the zinc-aluminum-alloy welding wire into the MIG welder and feed it through the welding tip by pulling the welding gun's trigger. With this finished, clamp the kirksite parts together in the manner in which they are to be welded using welding clamps.

3. Set the welder's feed speed and amperage according to the size of the kirksite pieces you're welding. Find this information either on the inside panel of the welder where you installed the welding wire or in the welder's owner's manual.

4. Attach the negative ground clamp to the kirksite part being welded, and then lower your welding helmet.

5. Position the welding electrode above the junction where the two kirksite pieces will be joined, and then pull the trigger of the welder. At the base of the electrode, you will see a pool of melted aluminum alloy form. Move the welding gun in small circles until this pool is approximately ¼ of an inch in diameter.

6. Push the pool of metal along the joint between the two pieces of kirksite while making small stitching or circular movements with the tip of the gun. As you move the gun forward, the deposited-weld electrode will fuse the two pieces together. After completing the weld, release the trigger of the welding gun and pull the electrode away from the kirksite part.

7. Clean the weld with the stainless-steel wire brush to complete the welding operation.

Tips & Warnings

• Grinding the weld to match the surrounding metal can be accomplished with a die grinder, if necessary.

• Wear appropriate safety clothes when welding any metal. Most important of all is to make certain that you wear a functional welding helmet to protect your eyesight from the intense light emitted during the welding process.

References

• "Welding Complete: Techniques, Project Plans & Instructions"; Editors of CPi; 2009
• "Welder's Handbook, Revised: A Guide to Plasma Cutting, Oxyacetylene, ARC, MIG and TIG Welding"; Richard Finch; 2007
• "Welding Fundamentals"; Roger Jellison; 1995