Joining Aluminum without a TIG

Tim Wescott · 2010-09-13T00:13:41+00:00

I'm kinda thinking of making a model airplane muffler or two. These days the things are generally cast in one piece -- but that isn't going to work for a one-off.These things have a header that comes off of the engine, then goes into a tube-shaped expansion chamber. See some examples here:'m thinking that I can fabricate one of these with a machined header, machined ends, and a section of tube. But it'll all be aluminum, so how to join the pieces?I'm assuming that JB weld won't take the heat and will just fall off. But I'm ready to be corrected.I don't have a TIG welder, or I'd just select TIGable materials and be happy.I do have an oxy-acetylene set, and I certainly know how to solder.So -- will aluminum brazing work on this? What sort of selection do I have as far as difficulty vs. results goes? Brands to look for? Avoid? Places to get stuff? I'd like something that's going to be as strong (or nearly so) as the parent material and that can be done on a welding bench with a torch and a vise.TIA.

Sep 13, 2010 46 Replies

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Artemus 16 years ago

That's a good point. I don't know either but it would be easy and quick to test. Art

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clare 16 years ago

The zinc type alubraze rods work pretty good - I've used "3.4.1 ideal rod" from amrelle Sales in Whitby Ontario to make canoe racks, bicycle racks tor the back of my camper trailer and a bunch of other stuff and have never had a joint failure.

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Paul Hovnanian P.E. 16 years ago

That makes sense. The strength welding will get you probably isn't needed in your application. You might want to check on the max temp. your assembly will see and compare that to the soldering or brazing process you are using.

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Tim Wescott 16 years ago

Having burnt myself numerous times on glow engines I can attest that they often get to 'Ouch', but rarely do they get to '@#$%ing Ouch'. Mufflers will go up to 'shiny spot'.

This is silver solder, which if I'm not mistaken melts way up there around 'browned spot' if not 'burnt black'. So I think I'm OK.

At any rate, we'll test it when we get it on the engine :-).

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clare 16 years ago

Melt temp on the 3.4.1 Ideal rod is 715 to 735 F

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Larry Jaques 16 years ago

I wholeheartedly agree.

-- Not merely an absence of noise, Real Silence begins when a reasonable being withdraws from the noise in order to find peace and order in his inner sanctuary. -- Peter Minard

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