That is about the area I would expect to see the edge of the heat affected zone on the weld....maybe hot cracking. I'm no aluminum welding expert but I have had the opportunity several times to be shown first hand that process variables in welding aluminum can get out of control real fast. There are a few aircraft mechanics and such on here that probably have a better opinion. High strength thin wall aluminum tube and large forged ends is pretty difficult to control. If you're not quite ready to switch back to steel, you might want to salvage the ends and see if another shop can re-tube it. Best of luck Cleaver
Frank, did it break at the weld?.. If it did, the weld did not have enough penetration. The weld should be the strongest point. Before you go steel take the drive shaft to a good welding shop that will bevel each end and put a root pass (inside bead applied from the outside) with multiple filler passes. If done right, the shaft will twist before the weld breaks. Nick
i am going to take this to a ...pro. welding shop...tomorrow and get a reading on what happened... met my friend Earl for breakfast (pancakes) and he brought me a driveshaft. i came home and put it in..."on the road again" .. Thanks Earl :Handshake EFF...
the guy said "the weld came loose." as in it didn't burn in...he took the ends and is going to retube it... will pick it up about 3:00pm tomorrow..:bananaman ...
If you look real close at the picture, you can see the weld about 1.5" infront of the break. The tube broke at the end of the yoke, well away from the HAZ. If I would guess, the tube should be replaced by some better aluminum, because whatever alloy that is can't take it. Probably 2024 would be a good choice.
