How to Repair Aluminized Stainless Steel with Super Alloy 5

How to Repair Aluminized Stainless Steel with Super Alloy 5

Aluminized stainless steel is a low cost alternative to high-strength steel. Consisting of stainless steel hot-dipped in aluminum and silicon, aluminized steel resists corrosion and is utilized in the manufacture of automobile and motorcycle mufflers, ovens and stoves, heat exchange units, HVAC units, and water heaters.

Repairing aluminized steel can be challenging, as standard stainless steel products are ineffective on the aluminized coating. Fortunately, Super Alloy 5 aluminum rod and flux kit eliminates this problem and creates a 30,000 psi weld strength bond at only 600°F.

There’s no need to pre-clean the aluminized steel, Super Alloy 5’s flux both cleans the metal and prepares it for bonding.

To repair the aluminized steel, first dip the rod into the powder flux and apply the flux to the work area.

Using your torch, broadly heat the parent metal. Super Alloy 5’s specially formulated flux acts as an exact temperature guide, liquefying when the parent metal reaches the 600°F working temperature.

When working on aluminized stainless steel, it’s important to keep the heat moving to avoid overheating and melting the part. If possible, heat from the backside or underneath to evenly heat the base metal.

When adding the rod, be sure the heat the base metal and rod at the same time. Remember if you remove your heat, the aluminized steel will cool quickly.

Continue to add rod, using the flux to flow the alloy front to back and seal any pinholes.

After completing the bond, allow the part to cool naturally and clean any residual flux with warm water and a wire brush.

Super Alloy 5 achieved a complete bond front to back with no pinholes or porosity.

A quick polish on the joint reveals a beautifully finished result.


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