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Aluminum Welding | Muggy Weld.com



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.


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.


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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These days, more and more parts are being replaced with aluminum parts. Why? Aluminum is lightweight, durable, and inexpensive in comparison with other metals. The problem is, most aluminum repair shops have been trained to believe that expensive machinery is needed to properly weld this versatile metal.


Aluminum melts at 1218°F. Unfortunately, it does not turn red like other metals before it reaches the point that it liquefies. If you have ever tried to weld aluminum you know that without an accurate temperature guide, you may end up cleaning your aluminum off the floor. For this reason, most shops in the past have recommended replacing aluminum parts rather than repairing them—which is not only expensive but unnecessary. Fortunately, times have changed.


Our unique line of welding alloys and fluxes for aluminum repair work synergistically to act as an exact temperature guide when welding aluminum. While many aluminum brazing products are sold without flux, we believe the use of flux to be superior for several reasons.


First, it allows the rod to flow better than aluminum rod alone. Any welder knows that flow is an important factor in successfully welding aluminum. Also, our flux acts as an exact temperature guide: Our Super Alloy 5 turns from powder to liquid at the exact moment when the rod should be applied. One the other hand, our Super Alloy 1 starts as a liquid and turns brown when ready for the rod. Finally, our Alloy 5 flux chemically reacts to clean up oxidation as well as other contaminates, which is very unique in the aluminum repair business.


Whether you are welding close to heat sensitive materials and need a super low solder or are welding through dirt, oil, paint or grease, our welding alloys allow you to weld aluminum quickly, easily and inexpensively with your own torch at less than half the temperature aluminum melts.



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



  Super Alloy 1 Super Alloy 5

Melting Temperature


350° F 600° F

Bonding Strength


20,000 PSI 30,000 PSI

Can be polished?


Fair Excellent

Can be plated?


Yes Yes

Takes powder coating?


Fair Excellent

Recommended Torch


Propane, MAPP, butane, oxyacetylene      Propane, MAPP, oxyacetylene

Can weld thick aluminum


No Yes, with oxyacetylene

Can join aluminum to other metals
(brass, steel etc)


Yes No

Can repair radiators without burning fins


Yes No

Metal Warpage


No Potential

Can be used with TIG


No Yes



Honey Liquid, 2 year shelf life Powder, 1 year shelf life

Pre-cleaning necessary?


Yes No

Diameters Available


1/8", 3/32" 3/32", 1/16"

Can repair cast aluminum


No Yes

Can repair aluminum boats


Fair Excellent
Demonstrated on pop cans at the county fair NEVER NEVER


Note: MuggyWeld alloys are not the same formulation as DuraFix, HTS-2000, Alumalloy, TechnoWeld, the pop can repair rod, or any other aluminum welding rod on the market, and the difference goes beyond our flux.


Our rods are specially designed to enable anyone to complete aluminum repair projects quickly and easily--with no special skills or tools.


For more information on aluminum welding, aluminum brazing, and aluminum soldering, and to watch instructional videos, click the links below:

Aluminum Videos

Cast Aluminum Intake Manifold Brazing

Cast Aluminum Intake Manifold BrazingNew!

Video showing how to repair a cast aluminum intake manifold.

1965 Chevrolet Impala SS Aluminum Cove Mouldings Repair

1965 Chevrolet Impala SS Aluminum Cove Mouldings Repair

Occasionally, aluminum parts are polished too aggressively, resulting in burn through, as is the case with these 1965 Impala SS Cove Moldings.

Soldering Stainless Steel to Aluminum

Soldering Stainless Steel to Aluminum

How to join aluminum to stainless steel. Super Alloy 1 can also be used to join pot metal, zinc die cast, lead, bronze, steel, copper, or brass--in any combination.

Aluminum Boat Dent Repair

Aluminum Boat Dent Repair

Proper brazing technique is discussed, as well as how to choose a torch for brazing your aluminum boat--without special machinery or disassembly.

Aluminum Boat Seam Repair

Aluminum Boat Seam Repair

Aluminum boats can be problematic in many ways: cracks, holes, rivets, seams etc. Repair your aluminum boat quickly and easily with Super Alloy 5 aluminum rod and flux.

Aluminum Boat Rivet Repair

Create a water-tight, air-tight seal around leaky rivets with Super Alloy 5 and an oxyacetylene torch.  Never settle for temporary epoxy repairs again.

1967 Ford Mustang Hood Molding Restoration

Super Alloy 5 troubleshooting, tips, and correct brazing techniques are demonstrated on an aluminum hood molding.

Aluminized Stainless Steel Welding

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

3003 Aluminum Welding Techniques

3003 aluminum is a non-heat treatable alloy used primarily for sheet metal work, duct work, and chemical equipment, as well as in the manufacture of a wide variety of aluminum parts. Super Alloy 5 is used to braze the aluminum with weld strength.

Aluminum Plates Soldered at Weld Strength Using Super Alloy 5

Brazing two thin aluminum plates at over 30,000 PSI using Super Alloy 5 rod and flux. First wire brush your aluminum to remove the oxides, broadly heat your base metal and add your flux with the torch.

Aluminum Radiator with a Hole Repaired with Super Alloy 1

We are repairing a hole in an aluminum radiator with Super Alloy 1, low temp solder. We cleaned the area with a dremel tool and used a propane torch and Super Alloy 1 to seal the hole.

How To Repair a Hole in Aluminum Tubing with Aluminum Brazing Rods and a Propane Torch

Demonstration of how to fix two holes in an aluminum air conditioning tube with Super Alloy 5 rod and flux. One of the holes has not been cleaned before soldering or brazing.

How To Braze or Solder Aluminum Together with a Propane Torch at a Very High Strength

Demonstration of the strength of Super Alloy 5--we soldered two aluminum plates together only using a very small amount of rod and flux. John of (John Barrett Works) invited us up to his shop to assist with some aluminum brazing and was also kind enough to hold the camera while the soldering was taking place.

Aluminum Tubing Repaired with a Propane Torch

2 holes in an aluminum tube are soldered with a torch using Super Alloy 1 soldering rod and flux. This demo shows how easy it is to fix any thin aluminum with no burn thru or distortion of the parent metal. Aluminum doesn't turn red like most metals so it is hard to tell when you are going to ruin the aluminum part.

Aluminum Tubing Soldered to Galvanized Steel Using Super Alloy 1 Low Temperature Aluminum

Super Alloy 1 multi metal solder joins aluminum to galvanized steel at 350 degrees--a bonding strength of 20,000 psi. The low melting solder uses a separate flux, dip the rod into the flux and drip or paint your parent metal with our unique liquid flux.

Aluminum Welding, Brazing & Soldering Tips: Join Brass to Aluminum

Yes, Super Alloy 1 can solder brass to aluminum. In this clip we join these 2 metals and demonstrate the strength of the repair.

Aluminum Welding Tips: How to Fill Large Holes in Aluminum

In this video clip, Mike fills a dime-sized hole in aluminum with Super Alloy 5 and an oxyacetylene torch.

Aluminum Bumper Repair: Aluminum Brazing

A 7 inch cut in an aluminum bumper reinforcement is welded with Super Alloy 5. We have posted this video at a sped up rate due to the length of the repair.

Aluminum Welding Tips: Cast Aluminum Intake Manifold Repair

This Toyota Land Cruiser cast aluminum intake manifold had a 3 inch cut across it. Super Alloy 5 is ideal for fixing cast aluminum, so we used an oxyacetylene torch to make the repair. We recommend using oxy-acetylene on all thicker aluminum because it can sometimes be difficult to keep the base metal at the correct temperature with propane or MAPP gas.

How to Weld Cast Aluminum

A cracked cast aluminum transmission case is repaired with Super Alloy 5 and an oxyacetylene torch. Due to the thickness of the aluminum, we recommend using oxy-acetylene and a size 3 or 4 tip. Once you get the cast to the proper working temperature, the aluminum filler rod flows in wonderfully.

How to Weld Aluminum Air Conditioning Fittings

This clip shows how to join aluminum a/c fittings using the same material thousands of auto repair shops and auto air conditioning shops use daily. It is no longer necessary to wait up to a month for replacement parts for your a/c system. Super Alloy 5 is a quick, inexpensive solution to all your a/c problems, enabling you to make aluminum repairs yourself.

Welding Aluminum Pieces

2 plates side by side demonstrating how to fill gaps in aluminum with Super Alloy 5.

Aluminum Welding Strength: Super Alloy 5

After joining 2 aluminum plates we put the strength of Super Alloy 5 to the test. Watch as the plates are put into a vice, as well as an attempt at pulling the plates apart with pliers.

Aluminum Welding Tips: Aluminum Soldering vs Aluminum Brazing

In this clip: how to determine when to use propane and when to use oxyacetylene when repairing aluminum. Soldering vs. Brazing.

Aluminum Welding & Brazing Tips: ATV Radiator Repair

This clip is especially for ATV owners. It demonstrates an aluminum radiator being repaired repaired from a vertical angle with our Super Alloy 5 and an oxyacetylene torch. If you can get to the damaged area with a torch you can fix it without removing it from the ATV.

Thick to Thin Aluminum Welding

Often we are asked whether or not Super Alloy 5 can join thick pieces of aluminum to thin pieces. In this clip we join a heavy section of aluminum to a thin piece of tubing using an oxyacetylene torch.

Aluminum Welding & Brazing Tips: Joining Aluminum to Copper Tubing

Often in the refrigeration industry, it is necessary to join copper to aluminum tubing from an evaporator. Sound impossible? Our Super Alloy 1 makes it easy work..

How to Solder Copper to Aluminum

This clip demonstrates how to join copper to aluminum using Super Alloy 1, the 350o solder, with a propane torch.This technique is useful for many applications including: Home and Commercial refrigeration Metal Sculpting Ornamental Art German Auto Air Conditioning Repair Air Conditioning Repair

Aluminum Welding at 600 Degrees

2 aluminum plates being welded with Super Alloy 5. This demonstrates the flow of Super Alloy 5 as well as the capillary action (flow from front to back, side to side)

Aluminum Welding, Brazing & Soldering Tips: Vertical Aluminum Welding

How to video: MIke demonstrates how to weld aluminum a/c fittings with super alloy 5, the same product used in thousands of radiator and air conditioning repairs shops worldwide.

Welding Aluminum

An aluminum air conditioning return loop is welded with Super Alloy 5 aluminum rod and flux. Notice the filler rod's perfect color match in comparison with the parent metal--you cannot see the difference.

Aluminum Boat Holes Repaired Easily

An Aluminum boat is riddled with holes from corrosion from salt water. Steve is a first time muggyweld.com customer using the Super Alloy 5 and an oxyacetylene torch to make the repairs.

How to Weld Thick to Thin Aluminum

How to weld differing thicknesses of aluminum together.

Aluminum Welding Tips: Aluminum Boat Repair

Steve at Alternative Automotive makes a repair on a very corroded portion of his aluminum boat using Super Alloy 5. Hiring a welder to come out and make these repairs could have cost a fortune, but now Steve is able to weld all the holes himself at a fraction of the cost.

Heat Dissipation

Demonstration of how to protect your heat sensitive surfaces without disassembling your parts.

Aluminum Articles

Aluminum Soldering

Soldering aluminum using Super Alloy 1


Brazing Aluminum Bumper Guard

Which Muggy Weld aluminum rod is appropriate when restoring a 1959 Porsche bumper guard? Because Super Alloy 5 brazes and is great for large projects, while Super Alloy 1 is a multi metal solder that is used as a finishing rod and for small imperfections, both are excellent choices.


Aluminum Transmission Repair

Repairing a brand new Ford Tractor's transmission cooler, customer accidentally ripped the aluminum while tightening.


Welding an Aluminum Cylinder Head

This is a 1997 Ford F150 aluminum cylinder head with corrosion eating right through the aluminum. The replacement cost for this part was $2200.


Intake Manifold Repair

This Ford Ranger 2.9 L intake manifold had a broken EGR valve mount.


Aluminum Boat Repair

We've recently received several emails asking about aluminum boat, so we decided to run a photo series on this project since it was such a popular request.


Repairing Aluminum Air Charge Cooler

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.


Integra Gear Pickup Repair

A 1993 Acura Integra odometer gear pickup needs reattached.


Cast Aluminum Welding

This antique weather vane was damaged in the recent Gulf Coast hurricanes.


Joining Steel and Aluminum

Occasionally an application arises where it is necessary to join aluminum to steel. Most welders will tell you this can't be done, because they haven't used our Super Alloy 1 solder.



Diesel Aluminum Hydraulic Oil Tank Repair

This diesel Tow Truck jack-knived and ripped a cut into this aluminum hydraulic oil tank. This rig couldn't wait two weeks for a replacement tank on order.


Motor Mount Repair

This cast aluminum 2.2 liter engine block came off a 1996 Honda Accord that had been involved in a minor traffic accident.


Cool Blue Heat Paste

Heat protection really comes into play when metal parts are connected to or close to heat sensitive surfaces such as glass, rubber, paint, chrome, plastic etc.


Note: MuggyWeld alloys are not the same formulation as DuraFix, HTS-2000, Alumalloy, TechnoWeld, the pop can repair rod, or any other aluminum welding rod on the market, and the difference goes beyond our flux.


Our rods are specially designed to enable anyone to complete aluminum repair projects quickly and easily--with no special skills or tools.