Super Alloy 5 is an aluminum brazing rod that brazes all types of aluminum with any torch: oxyacetylene, MAPP gas, natural gas, oxy-MAP, or propane. Its versatility makes it a valuable tool for professional welders and DIY enthusiasts because it allows them to work without expensive, specialized equipment.
Super Alloy 5 creates a bond that’s stronger than the parent metal (30,000 psi) and that you can bend, drill, anodize, machine, plate, tap, or thread. This unique alloy is a perfect color match to aluminum, and you can apply it without base metal sagging, warping, or wrinkling due to its low working temperature. This low melting point is especially beneficial when you’re working with thin-gauge aluminum, as it reduces the risk of heat distortion to near zero and preserves the integrity of the base material.
Super Alloy 5 flows through tight-fitting joints, bridges gaps, builds up missing sections, and welds beveled parts using a brazing technique and hand held torch–producing corrosion resistant finished welds that are smooth and require little or no finishing. This unique flow characteristic allows for deep penetration and creates a solid, void-free joint. It’s a dependable aluminum welding filler rod for structural repairs and fabrication where strength matters.
You can use this aluminum brazing rod to TIG weld all types of aluminum. It’s especially effective with cast aluminum applications. Cast aluminum is a porous metal and can be difficult to weld without the proper tools. Many welding projects that use cast aluminum fail due to contamination that gets trapped in the weld pool. Super Alloy 5’s powder flux chemically cleans cast aluminum, removes oil and impurities, and enables the welder to TIG weld aluminum without porosity or pinholes. This makes it a superior cast aluminum brazing rod for repairing challenging parts such as engine blocks, transmission housings, and antique aluminum castings. It results in a clean, strong, durable repair every time.
Why Choose Super Alloy 5
Super Alloy 5 combines simplicity, precision, and durability. Designed for use with standard torches, it eliminates the need for expensive welding equipment while delivering professional-grade results.
Flows Like Silver Solder on thin aluminum
Works in Any Position, including vertical or overhead
Strong, Corrosion Resistant, and Easy to Use
Bonds Through oxidation, residual paint, oil, grease etc.
Makes an excellent TIG rod
Ideal for Repairing Aluminum Boats: seams, rivets, dents, propellers, and more
Excellent Wetting Action on cast, extruded, and sheet aluminum.
Creates a Permanent, Machinable Bond rated up to 30,000 PSI.
No Special Skills Required — ideal for professionals and hobbyists alike.
Super Alloy 5 flows through tight-fitting joints, bridges gaps, builds up missing sections, and welds beveled parts using a brazing technique and hand held torch, producing corrosion resistant finished welds that are smooth and require little or no finishing.
Super Alloy 5 can be used to TIG weld all types of aluminum, and is especially effective with cast aluminum applications. Cast aluminum is a porous metal and can be difficult to weld without the proper tools. Super Alloy 5’s powder flux chemically cleans cast aluminum, removes oil and impurities, and enables the welder to TIG weld aluminum without porosity or pinholes.
Learn How to Repair Aluminum with Super Alloy 5 – Complete Video Series
Kit Includes:
Starter Kit 3/32″ Diameter: Seven 18-inch rods and 1 jar flux
Full Kit 3/32″ Diameter: Twenty 18-inch rods and 1 jar flux
Starter Kit 1/16″ Diameter: Fifteen 18-inch rods and 1 jar flux
Full Kit 1/16″ Diameter: Forty 18-inch rods and 2 jars flux
Shelf Life and Storage
Store rods in a dry, sealed container, away from extreme temperatures and humidity, to retain their effectiveness for years. Super Alloy 5 flux maintains its consistency and performance for one year when stored tightly sealed in a cool, dry environment below 77°F (25°C).
How to Use Super Alloy 5
Prepare the Metal: Clean the aluminum surface with a stainless-steel brush until it’s bright and oxide-free. A clean surface ensures strong metallurgical bonding and reduces flux consumption.
Set the Torch: Use a slightly carburizing (fuel-rich) flame for efficient heating and minimal oxidation. Maintain a 4–6 inch stand-off distance and sweep the flame evenly across the joint.
Apply the Flux: Heat the end of the rod, dip it into the flux so it sticks, then apply the flux to the joint area.
Heat the Base, Not the Rod: Focus on bringing the parent metal to 600°F (316°C).
Watch the Flux: The flux will turn clear and liquid, and the aluminum will appear shiny when ready.
Apply Rod: Gently apply the rod to the heated metal — don’t press or overheat.
Build the Repair: Keep the flame on the work while you feed the rod, letting capillary action draw the alloy through the joint.
Cool and Clean: Allow the joint to cool naturally, then remove any remaining flux with warm water and a wire brush.
Tip: For thicker aluminum and marine repairs, oxy-acetylene provides the consistent heat needed to achieve complete bonding.
Common Applications
Super Alloy 5 is trusted by marine, automotive, and industrial professionals worldwide. Its versatility makes it the go-to choice for aluminum repair, restoration, and fabrication.
Aluminum Boats and Propellers
Cast Aluminum Manifolds and Brackets
Diamond Plate Aluminum
Aluminum Radiators, Condensers, and HVAC Components
Thin to Thick Aluminum
Transmission Cases
Intake Manifolds
What Our Customers Say About Super Alloy 5
Thanks for the product….you saved me $3300 on the a/c in my house. A screw had rubbed a hole in the condenser tube, and they said it couldn’t be fixed, had to be replaced. — Galen Tribble
My first try was not successful trying to seal the crack on the aluminum water tank, so I melted it off watched the video again and tried to do it the same way. I water tested the tank again and had success. The hot water heater for my boat is reassembled and ready to go back in the boat. Thanks for your help. I would recommend your product to anyone who wants to get the job done. — Barry N Bernstein, Bernstein Agency, Allstate Insurance Company
Got the aluminum rods and Super 5. Practiced on some aluminum tubing. I couldn’t believe what I saw on your videos. Looked too good to be true, but it’s truly amazing! I have very little welding/brazing experience and it works fantastic. -Mike Larson, My Mechanic, Inc.
Frequently Asked Questions
Which torch should I use?
Super Alloy 5 can be used with oxyacetylene, MAPP gas, natural gas, oxy-MAP, or propane. For large or thick aluminum sections, oxy-acetylene provides the best heat penetration. Note: An oxyacetylene torch is required for aluminum boat repair, cast aluminum, large or thick aluminum masses, or diamond plate aluminum.
How do I know when I’ve reached the right temperature?
When the flux becomes clear and flows smoothly, and the aluminum surface turns bright and shiny, the base metal has reached bonding temperature.
Can I use Super Alloy 5 on aluminum wheels?
Due to the technical expertise required, we do not recommend Super Alloy 5 for repairing aluminum wheels.
Super Alloy 5 vs. Conventional Aluminum Welding
Unlike conventional aluminum welding, which requires precise control of temperature and specialized equipment, Super Alloy 5 allows you to achieve strong, cosmetic repairs using only a hand torch. Its low working temperature helps prevent distortion and maintains the integrity of surrounding material.
No need for TIG or MIG welders
Faster setup and easier learning curve
Works well even on thin or irregular aluminum sections
Perfect for field repairs and non-structural joints
Summary
Super Alloy 5 is the simplest, most reliable way to repair aluminum quickly and professionally. With its low-temperature flow, excellent wetting, and high bond strength, it’s the trusted choice for aluminum repair in marine, automotive, and industrial applications.
Super Alloy 5 brazes aluminum at half the melting point of aluminum, with any torch: oxyacetylene, MAPP gas, natural gas, oxy-MAPP, or propane. The resulting bond is stronger than the parent metal (30,000 psi) and can be bent, drilled, anodized, machined, plated, tapped or threaded.
Super Alloy 5 can be used to TIG weld all types of aluminum, and is especially effective with cast aluminum applications. Cast aluminum is a porous metal and can be difficult to weld without the proper tools. Super Alloy 5’s powder flux chemically cleans cast aluminum, removes oil and impurities, and enables the welder to TIG weld aluminum without porosity or pinholes
Key Features:
Flows like silver solder on thin aluminum
Bonds at 600°F – half the melting point of aluminum
Works with: propane, MAPP gas, oxyacetylene
Filler rod bonds through paint, oil grease etc without pre-cleaning
Makes an excellent TIG rod
Note: An oxyacetylene torch is required for aluminum boats, cast aluminum, large aluminum masses, or diamond plate aluminum.
