Drive it and a six pack to jersey Tim, I'll weld it

 

Yes it can be done. I have done it myself several times. A good comentant TIG welder should have no problem. It will have to be absolutely spotless clean (no paint). It will make it easier on the person doing the welding if you know what alloy the aluminum being welded is. Also easier if the material being added is the same alloy.

 

If you don't think it can be done, go to the track at a NHRA national event, and when someone blows up, go watch them put there stuff back together. Welded alumiun blocks and heads are extremely commonplace. Some of the head guys that I know will actually weld in the ports to change the airflow velocity or port volume.

 

The only difficulty in welding cast aluminum versus billet is that, if it is a used part, oil gets into the pores of the metal and then boils and creates pinholes. Still it can be done, sometimes I will heat the area to be welded to about 1100 degrees with an O/A torch to burn out the impurities, then brush or blast it before welding..

When TIG welding aluminum, cleanliness is way ahead of Godliness.