Soldering Galvanized Steel: How to Bond to Aluminum Tubing

Learn techniques for soldering galvanized steel to aluminum tubing quickly and easily with Super Alloy 1 multi-metal soldering kit

A few days ago a client asked me “Can you join aluminum with galvanized steel?” Well, with Muggy Weld Super Alloy 1, yes you can. Super Alloy 1 is a low-temperature solder that flows at 350°F and can be applied with nearly any heat source: propane, oxyacetylene, heat gun etc Super Alloy 1 can join galvanized, pot metal, steel, copper, zinc, bronze, brass, pewter, and thin aluminum (except cast aluminum) in any combination, with a resulting bonding strength of 20,000 PSI.

First, dip the rod into the flux and apply the liquid repair area. Super Alloy 1’s flux transforms at its working temperature, indicating when to apply the rod.

To start, heat the aluminum evenly, moving heat from one side to the other. Aluminum dissipates heat faster, so I’m going to focus heat more on the aluminum, roughly 80% of the heat will be focused on the aluminum.

Continue to keep the heat source moving, to avoid overheating the repair and scorching the flux. When the flux turns caramel colored, apply the solder rod. You must allow the part to cool in air, because if you pour water on it, it will shock the metal and make the joint weaker. After allowing the part to cool, the remove any excess flux with warm water and a metal brush.

If we take a look at the other side, both sides have been fully penetrated thanks to Super Alloy 1’s specially-formulated flux. When in doubt, use more flux because it will make your job easier.

Now I am going to demonstrate the strength of this material. It’s a pretty tough material, I’ve never seen it break.

Another successful repair with Super Alloy 1!


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