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Aluminum Welding, Aluminum Brazing, Aluminum Soldering



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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Aluminum Welding:

Welding is the process of utilizing heat to join metals.  Aluminum can be successfully welded through a variety of mediums including stick, MIG and TIG.  Many welders consider TIG welding the method of choice for welding aluminum due to its low melting point and ability to conduct heat.


Super Alloy 5 can be used to TIG weld all types of aluminum, and is especially effective with cast aluminum applications.  Cast aluminum is a porous metal and can be difficult to weld without the proper tools.  Super Alloy 5's powder flux chemically cleans cast aluminum, removes oil and impurities, and enables the welder to TIG weld aluminum without porosity or pinholes


Aluminum Brazing:

Aluminum brazing is the process of joining metals using gas rather than electricity.  While TIG welding may be the method of choice for welding aluminum, there are instances when brazing aluminum is superior to TIG:


    working with thin aluminum

    applications that require a malleable bond rather than a brittle TIG bond


Fortunately, Super Alloy 5 can be used for both TIG welding and brazing aluminum.  With a melting point of only 600°F, Super Alloy 5 brazes aluminum at half the melting point of aluminum, with any torch:  oxyacetylene, MAPP gas, natural gas, oxy-MAPP, or propane.  The resulting bond is stronger than the parent metal (30,000 psi) and can be bent, drilled, anodized, machined, plated, tapped or threaded.


Aluminum Soldering:

Aluminum soldering uses low amounts of either electric or gas heat to join metals.  Soldering differs from brazing in that the solder sticks to the surface of the joint, creating a bond with a lower tensile strength.   


Super Alloy 1 solder has an extremely low melting point (350°F), and its liquid flux changes color to indicate when the parent metal has reached the proper working temperature-- preventing base metal damage and warpage.  

In addition to soldering aluminum, Super Alloy 1 can join brass, copper, zinc, bronze, pot metal, white metal, monkey metal, steel, die cast, and pewter--in any combination, at 20,000 psi.


Aluminum dissipates heat very quickly, therefore, Super Alloy 5 and oxyacetylene are required for all thick aluminum or large masses of aluminum.




Super Alloy 1
for pot metal repair and pot metal restoration, low temperature aluminum soldering, and joining dis-similar metals.


Super Alloy 5
for brazing, soldering, and welding aluminum.




Super Alloy 1 and Super Alloy 5 Products

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Super Alloy 5 Full Kit 1/16"
Super Alloy 5 Full Kit 1/16"

Super Alloy 5 is the 600°F aluminum brazing alloy--bonds at half the melting point of aluminum ..

Super Alloy 5 Full Kit 3/32"
Super Alloy 5 Full Kit 3/32"

Super Alloy 5 is the 600°F aluminum brazing alloy--bonds at half the melting point of aluminum ..

Super Alloy 5 Replacement Flux
Super Alloy 5 Replacement Flux

1 container powder flux (shelf life 1 year) ..