How To Braze Aluminium – Step By Step Guide

If you have ever wanted to know how to braze aluminum, then look no further!

In this blog post, we will teach you all about the process of brazing aluminum: what it is, how it works, and how to do it.

We will also include some helpful tips on safety precautions that can help ensure a successful experience.

How To Braze Aluminium – Step By Step Guide

Follow the steps to know how you can braze tig welder and tig weld aluminium.

  • Wear non-flammable clothing, gloves, and safety goggles before you begin the brazing process. Non-combustible materials are a must for this step as it is an intense heat!
  • Dry the area to be repaired. Clean away all dirt, oil paint, or other residues for a more effective and professional repair with aluminum brazing.
  • Brazing is an important process that allows for strong, durable joinery with less effort. Clamp or support the piece to be brazed before heating it so both surfaces will come in contact and you can witness your hard work overtime!
  • To apply flux, dip the brush into an all-purpose flux and use it to coat a filler rod. Alternatively, you can buy rods that are already coated with this substance so there is no need for dipping them in anything.
  • Heat the metal until it starts to turn orange. This is when you know that your flux has been applied properly and will work as a binding agent for future soldering or welding operations.
  • Fill the cracks or joints with filler metal by running a brazing rod along with it. The heat of the metal will melt into any area that needs repair and moves as needed to keep burning while you work on filling in those areas.
  • The flux will flake off after the filler material has solidified. Dip or pour water over it to remove any stubborn bits of hot glue that may be stuck on your project, and use a wire brush if needed!
  • Polish the metal with an emery cloth after it has cooled. This will remove any oils and prevent tarnish from occurring in future months or years.
  • It’s a good idea to coat the area with an additional rust-resistant coating before leaving it if you don’t want your hard work to be in vain.

Have I solved the crucial thing?

Dealing With The Oxide

In the past, people spent a lot of time trying to remove aluminum oxide layers from their parts in order to successfully braze them.

Commonly this would involve complex acid-cleaning processes and then attempting to keep surfaces as oxide free as possible by submerging them into tanks full of argon or nitrogen gas.

In the past, many peoples’ attempts at brazing aluminium components often failed due to efforts made with complicated cleaning procedures

However, that left surface impurities on both ends while also making it difficult for oxygens trapped under oxides which leads towards an unsuccessful bonding attempt between metal’s molecules.

As soon as the aluminum was exposed to oxygen, it would react and form an oxide layer again. The attempts at removing this never really worked out due to its highly reactive nature with oxygen.

It has been difficult for engineers of machines that need these parts because they have had a tough time finding ways around their quick reaction with the air in our atmosphere.

How can you braze aluminium in a stainless steel vacuum?

It didn’t take long for the aluminum-oxide layer to form again, making it difficult to remove.

 Aluminum is so reactive with oxygen that even efforts like cleaning and treating couldn’t do anything about its composition.

The process was ineffective because of how highly reactive aluminium is when combined with oxygen gases in the air;

This would cause a new coating of oxide on each part before any chance at removing them could be made possible.

ALSO READ: 4 Different Types Of Welding Processes

Brazing Fixtures

Nowadays, it is not uncommon for parts to be designed so that they are self-jigging.

The use of fixtures often results in an assembly which expands differently than the fixture and can lead to distortion or deformation within the part itself.

To accommodate this differential expansion, stainless steel springs along with a range of other materials such as mild steel have been used with these types of assemblies in order to keep them from warping.

When exposed to heat cycles repeated over time during production processes like furnace brazing operations or dip coating procedures.

An important consideration if one hopes their design will endure many manufacturing phases without issues regarding warbling due either improper equipment usage by workers on site (elevating temperatures too high) or fluctuating environmental conditions.

Dip Brazing

Dip brazing pots are heated internally by electric resistance.

Alternating current supplied from a low voltage, high-current transformer to pure nickel or alloy electrodes immersed in the bath heats up metals at temperatures of between 800 and 1,000 degrees Celsius.

In aluminum dip brazing operations specifically where molten flux is held in a ceramic pot at the appropriate dipping range for metal temperatures (500°C – 900°C).


Understanding the science behind aluminum brazing is key to a successful project. If you are not sure where to start, consider these five steps that will help your next brazing job be as efficient and effective as possible.

What other questions do you have about surface oxidation? How can we help with this process? Let us know!

We’re experts in metal fabrication of all types and sizes for manufacturers who want their products done right the first time – without any issues from improper bonding or oxidation on surfaces.

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