I did a test butt weld on two pieces of sheet aluminum. The weld was swollen and didn't stick. I had parts that sat on top of another piece of aluminum that actually acted as a heatsink, keeping it from getting too hot. I propped up the parts to be welded, this time without inserting another piece of aluminum, and when the material reached the right temperature the rod flowed effortlessly. The photo shows the weld after placing it in a vise and hitting it with a hammer. I'm very impressed with the strength.
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