Step 1

Preparing material

Aluminum is easy to work with. It is strong but quite soft and can be worked fine with a normal saw and abrasives. Consider woodworking tools such as a band saw and the sander

Step 2

Good sanding

It is important to properly degrease and sand the aluminum. Make any bevels on the ends to allow the aluminum to flow better later, creating a larger soldering area. Because of the beveled edges, aluminum can easily flow into this which only makes the joint stronger.

Important tip – notice

Good tools are half the battle

Aluminum soldering is not difficult. Following the steps correctly is essential. No flux is needed to solder aluminum. Bernzomatic has managed to make a very high quality aluminum soldering rod. This flows very well and is very strong. A Chinese “similar” product at Aliexpress absolutely does not flow. This will cause the aluminum to overheat and fall apart. Pay attention to this! Cheap is expensive.

Step 3

Aluminum heating and sanding again

Use the Bernzomatic burner to heat the aluminum. The soldering rods melt around 365 degrees celcius, the aluminum itself only at 700 degrees celcius. But be careful not to overheat the aluminum. This is because it does not discolor when it melts, the aluminum just melts away all at once.

While soldering, still occasionally use the wire brush to remove the oxide skin around the aluminum. With this, you make sure it adheres better. The faster the whole thing is soldered together, the stronger it will become.

Step 4

Soldering the aluminum

To check if the aluminum is hot enough, go over the joint to be soldered with the soldering rod, gently from top to bottom. At some point, you will naturally see that the solder rod is “sticking” a bit. Go over it with the rod a few times to fill the groove all the way nicely. Reheat the joint after this, so the solder soaks in extra well.

TIP

Proper heating through the material

Try to melt the solder rods only with the temperature of the aluminum you have heated and not with the flame itself, that way it will be a lot neater and you will get a stronger connection. If the object is not hot enough and then you heat and melt the rod itself, the aluminum will not flow properly. It creates lumps and not a nice tight solder.

Step 5

Heat briefly after soldering

If the first solder is placed then it is wise to burn the whole thing a little more. This ensures that the whole thing will “fit together” nicely. Do not heat it too much; the aluminum should not flow away.