Bond Thin Aluminum Parts at 350ºF with Super Alloy 1

117 Bond thin aluminum parts at 350º with Super Alloy 1 multi-metal repair kit.  Aluminum welding, brazing, and soldering tips and techniques are discussed–specifically how to bond thin aluminum tubing with a handheld propane torch.

If you’re repairing aluminum and aesthetics are important, Super Alloy 1 low temperature aluminum rod and flux repair kit is the ideal solution.  While many aluminum repair rods flow at temperatures dangerously close to aluminum’s 1221ºF melting point, Super Alloy 1’s working temperature is a low 350ºF–allowing anyone to bond thin aluminum radiators and tubing with no welding expertise.

In this video, an aluminum air conditioning tube with several puncture holes is repaired.  We used a propane torch for this thin aluminum demonstration, however, Super Alloy 1 can be applied with nearly any heat source:  propane, MAPP, butane, heat torch, oven, soldering iron etc.

The end result is a strong repair (20,000 psi) with no distortion or burn through of the aluminum.  For further heat protection, apply Heat Freeze Heat Paste to surrounding area to contain torch heat.

Super Alloy 1 rod and flux work together to bond thin aluminum–note the technique:

  1. Clean the aluminum just prior to soldering, to ensure a proper bond.
  2. Broadly heat the aluminum, and keep the torch moving.  This is especially important when working with thin aluminum, to avoid blowing a hole in the aluminum.
  3. Dip the rod in the flux and apply to the aluminum, generously.  Watch as the flux changes colors, indicating the aluminum has reached 350ºF.
  4. Apply the aluminum filler rod, continuing to continuously move the torch.
  5. Allow the part to air cool
  6. Remove any excess flux with warm water and a wire brush
  7. Polish, plate, shape, grind, or finish as necessary

The same technique can be used with nearly all white metals:

NotePlease observe all AWS Safety & Health Guidelines when using Muggy Weld products.