Kustomizer
Well-known member
I've been asked to try, I have soldered them before but tried welding them. This is art not structure.
Can I TIG weld copper to 6061 aluminum?
- Thread starter Kustomizer
- Start date
AJ H
Active member
Gut feeling says no. Not unless it’s by a physical method such as friction or explosive cladding. You should be able to braze them which should be better the soldering.
AJ H
Active member
That being said. I’ve not done it but TIG brazing looks like a nice clean method you could employ here.
Kustomizer
Well-known member
Her hope is not to have another color introduced at the seam
Mud
Well-known member
I read a method to weld AL to steel, involved putting silicon bronze (I think) on the aluminum, then welding the silicon bronze bead to the steel. I forget exactly and don't know how to find it now. Anyway, maybe there's a material like that that will bridge between the 2 materials. I once TIGged steel directly to aluminum, but it was an accident. 
Gordon Heaton
Member
Silicon bronze will bond with copper, but I can not imagine it would bond with aluminum. With the vastly different melting temps of Al and Cu, direct welding with TIG seems impossible. That part about no color change at the seam is a tough one. Any chance of a mechanical or adhesive fix (slotting/swaging, high tech epoxy)?
Herding Cats
Hardplates
No, not by conventional methods. Copper can be TIG welded to steel, stainless, exc but as fas I know off the top of my head the only dissimilar metal aluminum can be welded to is magnesium.
jz79
Active member
there are those low melting point aluminum brazing rods (~400C was the melting temperature if I recall correctly), I'm not sure what the exact composition is (google says aluminum+zinc), I've used them on 5xxx sheet, they end up quite similar in color to aluminum, a bit more shiny, al+zinc sort of suggests to me that it will stick to copper, so if the joint is kept small, no one should be able to notice the difference
Kustomizer
Well-known member
I will take this info to them and see, I like the epoxy plan but he said no.
If the joint is an overlap, maybe consider rivets too. You could maybe do something like c-sink both the aluminum and copper sheets, then hammer copper rivets to fill the c-sinks and grind flush if desired. If its relatively thin sheet, you could also do a folded seam. Might have to get more creative if this is a butt-joint; maybe a doubler with rivets.
Mud
Well-known member
That got me thinking about those rods, I googled aluminum solder and this came up - https://s-bond.com/solutions-and-service/dissimilar-material-bonding/
Gordon Heaton
Member
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jz79
Active member
I just tried to look it up and google returned lots of places where they seem to be used in HVAC industry, they braze aluminum radiators to copper tubing
if it is just a cosmetic part, then perhaps even regular tin solder could work, it will tarnish with time, but so will copper, getting it to stick to aluminum before it oxidizes could be tricky, I sort of remember I had some special flux for soldering aluminum somewhere that I had bought by accident, can test it tomorrow
Jashley73
Well-known member
Can you post a sketch of the joint to be welded, or rather joined?
Kustomizer
Well-known member
I have yet to see anything from them as to what they are trying to make, just an inquiry as to if I knew how
Kustomizer
Well-known member
It could be I didn't show enough enthusiasm
alphonso
Well-known member
Yeah, guy called and asked if I could install cam bearings in a Dodge V-8 block. Showed up yesterday with a dirty, greasy, nasty short block. No, I don't think I can install bearings until you bring me a clean bare block. Same engine that I removed broken exhaust manifold bolts from last week. Long block is available for $3500.
Mud
Well-known member
I used to build cars, also narrowed rears and etc. I remember a guy asked if I could get a bent center pin out of a 12 bolt chevy differential so he could get the axles out, he had given up with the equipment he had. I said I'd look at it if he brought it to me. He pulls in and hands me the keys to a Monte Carlo, says he's in a hurry to get back to his job at the courthouse and to call him when it's ready. Hard pass.