Aluminum Welding Strength Test

Strength claims are easy to make.  Putting a finished aluminum joint in a vise gives you something more useful to evaluate. In this video, two aluminum plates were joined with Super Alloy 5 aluminum welding rod and flux, then subjected to a simple shop strength test.

Muggy Weld offers two aluminum repair alloys for different applications:  Super Alloy 1 low-temperature solder and Super Alloy 5 aluminum welding and brazing rod.  This demonstration focuses specifically on Super Alloy 5 and what happens to a finished 30,000 psi bond when substantial force is applied to the joined aluminum plates.

Super Alloy 5 is used for demanding aluminum repairs, including aluminum radiator and HVAC repairs, aluminum boat repairs, and cast aluminum repairs.

Two Aluminum Plates Put the Joint to the Test

The test starts with a pair of aluminum plates joined using the Super Alloy 5 rod and flux kit.  Once the joint is complete, the goal is simple:  try to pull the plates apart.

Pliers are used first, but the bond does not separate.  The plates are then placed in a vise and compressed until they flatten.  The aluminum changes shape under the force, while the joined area remains intact.

The distinction is useful when evaluating an aluminum repair.  This test is not based on the appearance of the finished joint.  Force is applied directly to the joined pieces to see how the bond responds.

Even after the plates are squeezed flat in the vise, the Super Alloy 5 joint does not break.

 

How Super Alloy 5 Joins Aluminum at 600°F

Super Alloy 5 is an all-position aluminum welding and brazing rod with a 600°F working temperature, less than half the melting temperature of aluminum.  The alloy can be used for brazing and soldering aluminum and as a TIG filler rod, providing several options for aluminum repair depending on the equipment and application.

Super Alloy 5’s powder flux helps remove surface oxides and provides an important visual temperature guide. As the aluminum approaches the alloy’s working temperature, the flux changes from a powder to a clear liquid, signaling that it is time to apply the filler rod.

For step-by-step technique, see how to braze aluminum with Super Alloy 5. If you are having trouble getting the rod to flow or the flux to respond correctly, use our Super Alloy 5 troubleshooting guide. You can also learn more about how Super Alloy 5 flux works when brazing aluminum.

 

Working with the Joint After Welding

Bond strength is only one consideration in an aluminum repair. The finished joint may also need to be worked after the repair is complete.

Super Alloy 5 closely matches the color of aluminum, and the repaired area can be machined, tapped, drilled, threaded, or shaped.  The joints also have an extruded appearance and require very little finishing, depending on the repair and application.

These characteristics are particularly useful when an aluminum repair requires additional fitting, machining, or finishing after the aluminum has been joined.

 

When the Aluminum Bends Before the Joint Breaks

The vise test provides a straightforward look at the difference between deformation of the aluminum plates and failure of the joined area. Pliers are unable to pull the Super Alloy 5 bond apart.  Increasing the force by placing the plates in a vise still does not separate the joint.  Instead, the aluminum plates themselves deform as they are squeezed flat while the joined area remains intact.

While a shop demonstration cannot reproduce every load, temperature, vibration, or condition a repaired part may encounter, it provides a practical example of how the finished bond performs under substantial mechanical stress. For applications involving cracks, broken sections, or structural aluminum repairs, proper surface preparation, heat control, and filler application remain essential to producing a strong finished joint.

 

 

 

Disclaimers:

Before using Muggy Weld products, please review and follow the welding safety guidelines provided by the American Welding Society (AWS):  https://www.aws.org/Standards-and-Publications/Free-Resources/#YourResources.

Additional product safety information is available at https://muggyweld.com/safety-guidelines

Muggy Weld LLC shall not be liable for any loss, injury, claim, liability, or damage of any kind resulting from or related to (a) the use of this website or its contents, (b) the use or misuse of any welding products or services obtained through this website, (c) errors in or omissions in the information provided, (d) the unavailability or interruption of this website or its features, (e) reliance on any instructions, techniques, or demonstrations presented on this website.

Safety Data Sheets (SDS) are available upon request with purchase from MuggyWeld.com.

 

Updated 10/5/26

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