Zink-aluminum welding rods - cheap approach to fabricate good repairs

Aluminum welding rods allows non-professional user to make cheap repairs in aluminium and other non-ferrous metals, using just handyman gas torch. Aluminum is readily repaired by soldering, but it is not an easy task (article). The main feature of the alloy practicality is a low enough temperature (about 400 Celsius ) to avoid warping the base metal. Joints made with aluminum welding rod are bright, and is more capable than the aluminum.

The main convenience of using aluminum-zink welding rods is a low temperature. For the repairs there is no need in use TIG welding machine, small, cheap and portable gas torch is enough. TIG machine could burn through if your base metal is thin, make sluggish weld and ruin the surface details, aluminum welding rods make clean and precise repairs. Zn-Al brasing rods can be used with Mapp, Map/Pro hand torch and works with almost all non-ferrous metals.

Aluminum-zink welding won’t work on ferrous metals except galvanized steel, they also don’t stick to Stainless steel or 2000 grade aluminium, lead and tin. You need to scrupulously clean aluminum with wire wheel and solvent from oxidized metal, it should be shiny. Heat needs to be applied before welding and carefully whilst prodding/scratching around the weld area with the welding rod to watch for it starting to wet the surface.

And some final tips. Pre-tinning helps to achieve best results. Tin both parts separately. Remove pores and bubbles with brush, in this case you can use direct flame on alloy. With sides thoroughly tinned, assemble the details and flow in enough rod to fill the vee. Although the use of flux is not necessary, a good paste will make the joint stronger and welding easier (https://toolsglobe.com/welding/aluminum-welding-rods/).

You can use any heat source, but if the surface is large (like a boat bottom) or the joint is on heavy component, oxyacetylene or mapp torch are much better. You need to pre-heat the components, to test the correct temperature, rub the end of a rod onto the work, if the rod will flow when working temperature is reached. In any case don’t place the rod onto the flame, or the weld won’t be strong enough.

About Flaring

If you need to connect steel or copper tubes together, you can do it by soldering, welding or brazing, and sometimes it’s preferred or even required to do it mechanically. To create a mechanical connection on tubes flaring is used. Flaring is a process to form the end of a tube to make a liquid-tight or a gas-tight connection.

If you flare the tubing properly with the proper tools and right technique you’ll get the leak-proof joint The first thing is cutting the right length of tubing with a proper tool. the next step is to slide the compression nut on the tubing. The last step is to use a flaring tool kit to make a flaring itself.

Single flaring is the most common and the simplest process of flaring The single flare is available in both 37 and 45 degrees. Rotary or spinning the flared end, and a ram forming are two available ways to accomplish single flared tube end (https://www.bestflaringtool.com/).

Most of flaring kits are relatively inexpensive and easy to find, despite the fact that different sizes of tubes require specific sets of equipment. You need to use a proper cutting tool to cut a tube. A common flaring tool kit has two main parts – a flare form and a reamer. A flare form is like a clamp with a number of holes used for various tube diameters. It holds the pipe firmly so you can flare the pipe with minimum efforts A reamer has a conical point, a screw, and holding arms and makes the actual flaring.

The most common flare tube ends and corresponding flare fitting standards in use today are the 45-degree SAE style, and the 37-degree AN style, also used with the JIC system. For a given size, the AN/JIC style tubing generally has a higher pressure rating SAE and AN/JIC connections are completely incompatible due to the different flare angle. The refrigeration and air conditioning industry usually uses 45° flare connections while hydraulic hoses are usually 37-1/2° flare connections. According to NFPA 54/ANSI. Z223.1 National Fuel Gas Code, copper tubes used for natural gas, Liquefied Petroleum, or propane may use flared brass fittings of single 45°-flare type Nevertheless, all National Model Codes permit the use of flare fitting joints, the one should be consulted by the authority having jurisdiction (AHJ) to determine acceptance for a specific application

Sunglasses and UV radiation protection

Sun glasses are protective devices that prevent eyes damaging and discomfort by reducing bright light and ultraviolet rays (Partridge, Eric The New Partridge Dictionary of Slang and Unconventional English). They were also called "cheaters" in American slang.

The American Optometric Association suggests when purchasing sunglasses, consider the following: 99 to 100% protection of UVA and UVB rays; screen out 75 to 90 percent of visible light; gray or brown for proper color recognition. It is important to understand, that Ultraviolet protection and darkness are not the same. People with eye disorders such as cataracts, macular degeneration and retinal disease are especially susceptible to UV rays and should take extra precaution.

Polarization blocks glare, sunglasses with a special polarising film absorb horizontal light waves Having this chemical film on polarized shades, you are able to see more clearly. Besides boaters, skiers, bikers, golfers and joggers benefit the most from polarized sunglasses.

The United States Environmental Protection Agency (EPA) developed the ultraviolet Index, and to protect your eyes from harmful solar radiation, sun lenses should block up to 100 percent of UV rays. A pair of $5 sunglasses may filter out 100% UV rays just as well as a $200 dollar pair. Generally, more expensive lenses have higher quality and provide a sharper, clearer image with less distortion. The sun radiates Ultraviolet that arrives on Earth in wavelengths 320-400nm (UVA) and 290-320nm (UVB), both UVA and UVB can be dangerous to your eyes.

Ultraviolet (UV) rays are located just past the violet portion of the visible light spectrum and they can be harmful for your eyes; sunlight is the main source, so your a pair of sunglasses should filter them out. Glasses which do not filter out ultraviolet light can actually cause more damage to the eye than no sunglasses at all. This is because the darkened shades lead the eye to dilate, letting in more potentially harmful UV than usual. So when buying a pair of sunglasses, look for the percentage marking of ultraviolet blocking. Now many a pair of sunglasses block 99-100% of ultraviolet light

Pleased to meet you on my site!

I am Chris, I was born in Erie, and I am a mechanical designer.

I have made many different stuff and I have learned mechanics hands-on in a way that universities do not provide. Now, when I’ve got much experience, I became a part of the supportive fellowship that I can rely on, a gang of friends that I will promote my growth as a person and as an engineer.

To do truly something special I’ve begun this little tech blog and look forward to providing help and share my experience with the beginners (as I was some time ago) and enthusiasts in engineering. So, don’t hesitate to ask me any question, share your experience and even criticize me – I’m ready to have new experience and learn new things