Soldering Aluminum with a Propane Torch at Very High Strength

Soldering Aluminum with a Propane Torch at Very High Strength 1024x682 Soldering Aluminum with a Propane Torch at Very High Strength Soldering aluminum does not have to be a complicated
process. In fact, most jobs can be accomplished at home with very simple tools.
This is good news for folks who have been wary of investing in the equipment
necessary for aluminum welding. In many applications including pot metal
repair, custom vehicle work, and more, aluminum soldering (as opposed to
welding) with nothing more that a propane torch can produce strong and durable

First a note about materials: The only things required for
this job are a basic torch, some flux, and soldering rod. Be advised that not
all rods are created equal. Many will do the job better and stronger than
others. A little experimenting should quickly indicate which is which. A few
recommended products include BernzOmatic Aluminum Soldering Rod, Model AL-3,
Turner Brazing/Welding Rods, Rod #3, Cat A5040, and Master Marketing Products,

The advantage of soldering or brazing aluminum over welding
is that is requires less equipment: just a torch instead of an electric arc
welder plus accessories. If done correctly, soldering can offer a strong and
durable connection much more easily. Here are a few pointers as you get

As with any joining job, the first step is to clean all
surfaces that will be soldered. The most common way to do this is to use
rubbing alcohol and a wire brush. Cleaning your surfaces will allow proper
bonding to occur. You want the surface to be shiny and smooth, and you will
want to avoid contaminating the area with fingerprints.

When setting up the pieces to be joined, it is always a good
idea to secure them using some kind of jig unless gravity is already doing the
job for you. This is because pieces will tend to shift as heat expands the

While using flux is not essentially necessary, it often
helps to produce better results. This compound, applied to the joint before
adding heat, helps to clean the area while evening out temperatures. Using this
material can often help you to avoid problems with uneven solder flow.

When all is ready, you can use your propane torch to heat up
the metal. If one piece is bigger and heavier than the other is, direct most of
the heat there. The idea is to bring both pieces up to the right temperature at
the same time.

The secret to successful aluminum soldering, as opposed to cast iron welding   is breaking through the oxidization layer that naturally
forms as the metal is heated. The way to do this is to use the soldering rod
itself to scratch through this layer. The technique is to rub the rod into the
joint until adhesion is achieved. Usually this will require heating up the
metal and applying the rod alternatively until you achieve the correct

If many cases, the oxide layer will remain in a few areas,
and will prevent complete adhesion. This can be frustrating to first timers as
they try to fix the problem by adding more solder. This usually just results in
a buildup of material where you don’t want it. Your best bet in this situation
is to scratch through the oxide layer with a stainless ‘solder aid’ tool, and
then use heat to draw the existing solder into the gaps.

As with any joining technique, the best way to get a feel
for it is to practice. Using aluminum cans is a great way to get a feel for the
heat required and to develop good technique. With a little practice, anyone can
solder aluminum, and the best part is, it doesn’t require any expensive tools
or materials. 

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