Thank you for viewing one of the most unique and best kept secrets in the Aluminium Welding Industry.
Durafix is the most widely used rod on the market for WELDING ZINC BASE metals - white - die cast - pot metals. Welds made with the rod are clean and free from slag, and produces a sound joint which is stronger than the parent metal.

As with all welding systems there are three main factors involved:

1. Preparation
Preparation is the steps involved to "clean" the parent metals prior to heat being applied. The metal composition "Zinc Content" will be a large factor to consider when preparing to weld Aluminium or Zinc based items. This content will indicate the tensile strength or "how soft or hard" the alloy is? How much porosity, surface contaminants, oxides, or foreign impurities attaching themselves to the alloy are critical factors and is where "the pedal hits the metal"!

2. Heat
The type of heat recommended is generally defined by "tip size" and gas type. More pure gases such as Mapp or the introduction of Oxygen will generate more heat. Results may vary due to how the metal or items are held during the welding process, as clamps or a large steel vice can act as a "heat sink" drawing heat away from the repair area. The overall size or thickness of the item to be repaired versus the quality and quantity of the heat source can alter end results. Not all 'Alloys' react the same when heat is applied. We recommend Turbo Torch which produces on average 40% more heat than other brands!

3. Technique
Welding Aluminium or Zinc based items with Durafix soldering rods is performed without the use of flux, produces a joint sound and free from porosity. There is no need for years of welding experience. It's convenient and can be used by both novice and professional alike. We stress that there is nothing better than to practice, practice, practice! We recommend slicing the side of a fizzy drink/aluminium beer can with a fine knife and start soldering up the cans. Instantly you will start "reading" how much heat you are applying and before you know it you will impress your neighbours and friends with your new found skill!

Using other cleaning processes such as:
• Steel wire brushes (or other types) leave a carbon steel or residue on the surface impairing the adhesion of Durafix
  
• Carbon "metal grinding discs" may imbed carbon residue creating welding problems. Professional Aluminium welding technicians are sometimes found using "concrete grinding discs" & stainless brushes, as this reduces contamination.
  
• Sand Paper causes the pores of the aluminium and surface of the material to be contaminated with silicon or carbon residue therefore may inhibit Durafix to bond successfully to the parent metal
  
• Acid washing can cause future rapid oxidation within the pores of aluminium. This process requires immediate neutralising warming and Stainless Steel wire brushing when dry.
  
• Sandblasting or beadblasting can leave behind silicon or an inorganic layer creating a barrier.
  
• Polishing or Buffing Wheels can deposit "soaps and waxes" on the surface.

Durafix can be used to weld:
• Anodised Aluminium
• Powder Coated Aluminium
• Chromed Aluminium
• Nickel Coated Aluminium

Provided you remove these "coatings" in the areas to be repaired! Durafix can be anodised. Durafix can be re-chromed, however it is recommended that the welded area be nickel plated prior to chrome plating, as the acid from the anodising process leaves a blackish scar on the joint welded with Durafix.

When using Durafix Soldering Rods we recommend the technician to:
• Use a slightly carbonised or neutral flame (excess of acetylene), with small tip for most work.
• Heat the material that you are working on to 389°C (732°F) and then apply the rod (tinning) with rubbing action.
• Brush the molten rod thus "dragging out" or releasing further oxidation…recoat surface with rod.
• Keep the heat off the rod as it will not work if heated directly.
• Refrain from using excess heat, as this will cause Aluminium to "boil" and become brittle

• Rub & stir the rod into the pool of weld. This will help release trapped oxidation and create a stronger weld
• Oxidation will settle on the surface when cool, brush off and re-weld (eg aluminium boats/rivet areas)
• Slowly reduce the heat after completion of weld, as both metals have different cooling rates (reduces risks of cracking)
• Do not use Durafix on Magnesium. (To test for Magnesium shave a small piece of metal and apply the flame. If it burns white, then it is Magnesium).
• Do not use on Pewter or tin as they will melt before the working temperature is reached.
• Durafix can be used to bond galvanised sheet steel as it will bond to the zinc
• Durafix can weld copper to aluminium (eg field wires in motors/generators)
• Stripped threads - heat and stir in rod 4-5 minutes to release oxidation, then set bolt in molten rod, wind bolt out when cool
• Use panel steel to capture or hold molten rod as it will not stick to mild steel (use for boat prop repairs)