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How to Solder an Aluminum Air Charge Cooler

Testimonials

Mike,

These pics come from a new aerospace test facility that they are constructing at the University of Notre Dame. The SSF-6 is working great.

 

aluminum welding and metal repair

I am attempting to make all of these fittings air tight as they are used for pressure measurements. We can¹t have any leaks. I had very little warpage of my base metal and I think this is really going to work out very well.

 

metal fabrication and repair with muggyweld

Thank you,

 

David Hipskind
Turbomachinery Technician
The University of Notre Dame
Institute for Flow Physics and Control (FLOWPAC)
The Hessert Laboratory for Aerospace Research

 

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This air to air aluminum air charge cooler was scrapped by a trucking repair company because of a tiny hole in one of the tubes.

 

 

We cleaned up the hole with a wire brush to prepare the base metal.

 

 

Gently applying heat, we watched for the flux to turn root beer brown and applied our Super Alloy 1 rod.

 

 

Notice there is no fin damage due to the low heat of the Super Alloy 1 solder. We applied a little extra flux to help the solder flow.

 

 

After removing the flux with a little warm water and a wire brush, this $1200 part is ready to re-install.

 

 

TIPS:

 

Dont throw away repairable parts--use the same product these shops use, and make these repairs for a fraction of the price.

 

Do no apply heat to the rod itself, broadly heat around the rod to improve flow.

 

Super Alloy 1 Products

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Super Alloy 1 Starter Kit 3/32"
Super Alloy 1 Starter Kit 3/32"

Super Alloy 1 is a multi-metal solder that joins all white metals including pot metal, zinc die cast..

Super Alloy 1 Starter Kit 1/8"
Super Alloy 1 Starter Kit 1/8"

Super Alloy 1 is a multi-metal solder that joins all white metals including pot metal, zinc die cast..

Super Alloy 1 Full Kit 3/32"
Super Alloy 1 Full Kit 3/32"

Super Alloy 1 is a multi-metal solder that joins all white metals including pot metal, zinc die ..

Super Alloy 1 Full Kit 1/8"
Super Alloy 1 Full Kit 1/8"

Super Alloy 1 is a multi-metal solder that joins all white metals including pot metal, zinc die cast..

Super Alloy 1 Replacement Flux
Super Alloy 1 Replacement Flux

1 Jar of Honey Liquid Flux (shelf life 2 years) ..