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Best Aluminum Welding Rod


Best Aluminum Welding Rod


ALW - 775 Repairs:

  •  Aluminum

  • Cast Aluminum

  • Zinc Magnesium

  • Cast Magnesium

  • Pot Metal

  • White Metal

  • Galvanized Metal

  • Copper-Brass

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Brazes Aluminum and Magnesium Alloys

 ALW-775- is a "second generation" fluxless low-heat brazing rod for aluminium. This includes cast aluminum and magnesium. ALW-775 will join all aluminum alloys, including those that are not successfully joined by high temperature brazing. When drawn over heated aluminum, ALW-775 penetrates the aluminum oxide affecting a chemical bond that is stronger than the original commercial aluminum. The electrode potential between ALW-775 and aluminum is so slight that electrochemical corrosion is not a problem. The ALW-775 joints will last permanently in normal or protected enviroments and have lasted 10 years longer in sever conditions.


Best Aluminum Welding Rod


General Information On Aluminum

Follow these three easy steps and you will create a strong, perfect weld every time.


Step One: Clean the area with a file, grinder, or wire brush in order to remove any paint, dirt, or oxidation. This 2nd generation welding rod does not require a special brush to make it work.


 Step Two: Heat the working surface not the rod until the work surface is hot enough to melt the rod, just as if you were soldering or brazing. DO NOT PUT THE ROD IN THE FLAME . The pore structure of the metal to be welded must be opened with heat in order for the rod to penetrate the work surface. Check the surface temperature of the aluminium by striking the rod across the surface (just as if you were striking a match). You will not see a color change when heating the aluminium so check the temperature frequently.


The tinning process: Once the base metal melts the ALW-775 rod, rub the rod briskly across the surface

(as if running a crayon across a hot skillet) this breaks up the surface tension between the rod and the base metal and creates a strong  bond.


Step Three: When the weld is completed always allow it to cool naturally back to room temperature.


Pot Metal, White Metal, and Galvanized Metal

These are all zinc based metals, and all melt at approximately the same temperature as the ALW-775 rod. When items are made out of pot metal and white metal they are typically poured into a mold. When working with these items, in order to retain their shape, it's best to place the pieces in a moist box of sand, or a piece of clay. This acts as your mold. Work directly in the flame without preheating the work surface. Pot metal and white metal will sometimes take a little longer to reach their melting points than the ALW-775 rod just because they represent a larger volume of metal than the rod does. On galvanized metal heat the rod at the same time, but because galvanization is actually a zinc coating and is very thin it will tend to melt a moment before the rod. So once the rod begins to melt start regulating your heat to avoid scorching the galvanization. Before attempting to repair expensive or antique parts spend some time practicing on similar types of metal or pieces.


Vertical and Overhead Repairs

Normally on overhead and vertical repairs you are unable to apply as much rod to the work surface as if you were working on a flat surface. So start out by tinning the surface with a small amount of rod and allow it to cool slightly. Then come back and build up your weld by softening the rod in the flame then laying it on the tinned area and then bringing that area up to 700°f. When the rod reaches a liquid state it has a great deal of surface tension to it and attaches bak to itself rather easily. Vertical repairs can easily be done by alternating the rod and the heat and starting at the bottom and stacking the weld on top of the tinned area.

Cracks, Thick Pieces, and Castings

Propane works well on thicknesses up to 1/4". On heavier pieces or to save time oxegen acetelyne is acceptable. Always make sure you have the torch adjusted to a clean burning flame. A rosebud tip is recommended. Cracks should be V'ed out through thhe thickness of the metal. Preheat the surrounding area to be repaired to 500°f. Heat immediate area and tin. The desired thickness and strength can be achieved by softening the rod and applying to the tinned area and bringing the temperature up to the melting point of 700°

Joining Pieces and Lapping

Often two pieces of different thicknesses are difficult to join together using regular brazing techniques. Try this method: Tin both peices seperately. After tinning position or clamp both pieces together and reheat. Once the tinned area reaches 700° the rod will attach back to itself (it's just like glue with heat). This is a great way to put a large patch on a boat or a piece of irrigation pipe. On Larger patches roll the on like a sticker start heating at one end and pressing down as you go. Holes up to 3/8" can be bridged entirely using ALW-775 rod.

 Heat Stops

When you have work that is close to another repair in is a good idea to use a 'heat stop'. This can prevent older work from being seperated. There are several comercial heat stops available. You can also use a wet rag, mud, clay or for smaller aplications paste-type toothpaste.

Thread Replacements

Stripped out threads can be easily repaired by using either of two methods.

Method One:Drill out old threads oversized about 1/8". If the hole is open on the bottom, seal off using steel wool or other steel (such as a coffee can lid). Place a good quality black steel bolt in the hole. Begin heating until both the bolt and the basemetal are hot enough to melt the rod. Push the rod down around the bolt until slightly overfilled. Position the bolt for alignment and allow to cool. When cool, break the bolt loose with a wrench and remove. This method will not work on small bolts simply because of the torque necessary to remove the bolt.


Method Two: (This method is preferred). Drill out the old threads, not necessarily oversized. Seal off, as in method one and heat base metal until hot enough to melt the rod into the hole and fill. Allow to cool, file until smooth. Center punch, redrill and tap. This second method gives a superior set of threads and is reccomended in most applications.

Spark Plug Threads

Clean thouroughly with rotary file or brush. Using oxygen acetylene, heat the area around the hole, wipe inside of the clean hole with ALW-775 rod until a layer that is equivalent in thickness to the missing threads has been obtained. Use a thread chaser to establish new threads when cool. be sure to turn engine over a number of times with plug missing to exaust any debris.

Filling a Large Hole

Start with a clean area, tin the entire inside of the hole. Now clamp a piece of steel to the backside of the hole. Once the hole as been tinned you can work right in the flame with the rod you are merely adding rod to the existing rod and this can be done at 700°. When the hole is full allow to cool and machine til smooth. also to save the rod, try cutting a patch for the inside of the hole.

Propeller Repairs

On rough edges begin by clamping a piece of steel on the back side, tin the edge of the blade and begin to build up to desired size and thickness. After the prop cools machine to size and place on bearing or nail. The heavy blade will tip down some take of some of this blade, or add to the other blade to achieve balance.

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