Aluminum soldering seems easy to listen and understand but double the difficult for actually performing the process. Tight process control is essential when you are soldering aluminum, as any conventional approach to do so is made extremely difficult by the tenacious aluminum oxide. In addition, you need to take extra care when you are choosing the alloy because potential galvanic corrosion incidences cam happen due to the aluminums potential dissimilarity to many conventional solders. With different varieties of gauges, alloys and tempers the results of aluminum soldering greatly differ.
When you are soldering aluminum, to aluminum copper the secret of its success lies in the flux you use for the process. First thing you have to do is clean the aluminum surface that needs to be soldered then the flux you are using should be fluid and effective for the absorption of oxides and other contaminants present on the soldering surface. In addition, the flux should be eligible enough to prevent re-oxidation of the cleaned surface and for this, you need to apply thin continuous layer of flux on the soldering surface for better adherence.
When you actually perform the aluminum soldering process then you need to cover the entire soldering area with thin layer of flux and then start heating the fluxed area. When the flux starts to bubble, you will have to apply the solder to tin the surface. When you are soldering two pieces of aluminum or piece of aluminum with the copper, you need to equally tin both the soldering surfaces. When this is done, you just have to stack the two tinned surfaces together and then start heating it with the aluminum-soldering device. This will give rise to the good solder joint without the use of additional force or additional soldering as the two tinned surfaces flow together.
Always when you are working on aluminum soldering make sure that you apply enough heat because you might run the risk of running cold solder joint. In addition, always make sure that the aluminum soldering surfaces are clean and they are maintained clean during the process to prevent possibility of bad solder joint.
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