How to solder aluminum. Encyclopedia of radio electronics and electrical engineering
Encyclopedia of radio electronics and electrical engineering / Ham Radio Technologies
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Aluminum is one of the most convenient materials in design practice. Slightly inferior in strength to steel, it is much easier to process, has good electrical and thermal conductivity, and a beautiful appearance.
However, the main problem that amateurs have when working with aluminum is its soldering. It's just that aluminum doesn't solder. The reason for the impossibility of soldering aluminum by conventional methods is the ability to form oxide films very quickly (in fractions of a second) in air. Therefore, previously developed technologies require either special mercury fluxes or special replacement tips for soldering irons.
Most often, the need for aluminum soldering arises during the repair of resonant voltage stabilizers. In order to save money, all windings of industrial network stabilizers are made with aluminum wire. It is not necessary to solder the wires themselves. It is enough to screw a well-soldered wire to them in any way convenient for you (see the figure) and solder not aluminum, but this wire.
But what if it is necessary to solder not conductors, but, for example, the most inconvenient flat surfaces for soldering?
The proposed method is carried out using conventional solder and rosin with a conventional soldering iron. Since aluminum conducts heat very well, it is better to take a powerful 60-100 watt soldering iron. If your soldering iron does not have enough power to heat up large parts to be soldered, use additional parallel heating using a gas or electric stove.
Before joining, the soldering place should be thoroughly rubbed with some crumbling stone (sandstone, brick, a piece of dried mortar containing sand, etc.). The stone cleans the surface of aluminum from a thick oxide film. Sand and dust generated during the cleaning process must be left at the place of soldering. Immediately after rubbing, the aluminum surface is covered with a layer of molten rosin.
Further, the soldering technique differs little from the soldering of conventional materials, except that now the soldering iron tip must be thoroughly wiped to destroy the thin film of oxides that have formed on the cleaned surface before applying the rosin with sand.
The strength of brazed aluminum is higher than that of brazed copper. This is explained by the low melting point of aluminum (much lower than that of copper), as well as the great ability of aluminum to diffuse into other metals.
Among all aluminum soldering methods known to me, this method is the simplest, cheapest and most effective. It is also suitable for soldering any other metals.
Author: Yu.Borodaty
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