Robotics Team needs aluminum welding Help

Metal Shop
#1

Hey y’all the high school robotics team I mentor needs some help welding an aluminum arm together.

Here is a picture of the arm that needs to welded together:

The arm need to be redesigned somewhat but that is the general shape and construction. The arm will be made of 0.125 inch wall 6061 tubing, 0.125 and 0.25 inch thick gusset plates in 5052 and 6061 and .25 thick ‘L’ brackets in 6063. Most of the plates and brackets will be pop riveted into place to make fixturing easy. The whole arm will then be powder coated so welds don’t have to be amazing they just need to hold.

Let me know if you can help.

Here are some pictures of robot and team:

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#2

If the weld fails what’s the worst thing that could happen? Would anyone be injured or would there be any monetary loss?

Would you be willing to provide a statement holding the welder harmless of any defects in the weld?

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#3

The worst that could happen if the arm fails is for the robot to fall onto the ground. We have tested this with our current arm and the robot is unharmed.

We are more than happy to provide such a statement.

Edit: I am happy to bring case of beer and BBQ dinner for anyone who can help us with this.

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