Durafixrepair rods are 475mm long, are on average 3mm X 4mm and are oval in diameter.

Durafix is a unique and unrivalled Fluxless Aluminium Repair System not to be confused with Hermetic Welding (gas shielded fusion welding) or gas (fusion) welding. Durafix places an easy aluminium welding process in the hands of DIY or Mechanical Engineers who do not own or have access to expensive welding apparatus and specialist gases.

We do not promote Durafix repair rods to replace existing commercial welding practices; we promote a unique and simple aluminium repair system that overcomes many technical barriers.

The unique Durafix weld system utilizes a low heat source available from inexpensive LPG, Propane, Mapp or hotter oxy-acetylene gases. Molten Durafix enters the pores of the heated parent metal which remains in a solid state. Durafix rods will only successfully adhere to surfaces that are ‘ground or filed back to fresh material’ and then cleaned with a Stainless Steel (S/S) brush. Due to the purity of S/S, it is the only type of brush that can eliminate oxides, salts or contamination that create a barrier between the repair rod and alloy. On average the porous-free welds can be found 70% stronger (at minimum) than base Aluminium. When correctly used Durafix welds can be of higher tensile strength than Tig welds. This is because the composition of Durafix is much ‘denser’, harder and free from porosity compared to aluminium. Also due to the use of a low heat of 389° C the composition of aluminium is not annealed-softened (600° C) or crystallized-weakened (1100° C). Although the welds can be found stronger than commercial aluminium welding, the inexpensive Durafix repair system is akin to other simple brazing or soldering techniques. Experienced engineers will use Durafix rods when extreme heat generated by Tig welders cause cast aluminium or die-cast to “break up” or explode. Durafix is the original, most reliable and easy to use weld process able to repair paper thin aluminium such as radiators, condensers or the smallest of lightweight items. Durafix rods can weld any aluminium irrespective of overall size, thickness or shape. Very large items will require more heat, this is done by using ‘hotter gases’ and commercial type torches. Durafix will weld copper to aluminium. Durafix is much denser, stronger and free from porosity, therefore is well suited to submersion in saltwater.

I would recommend the purchase of one of our quality large S/S brushes. The small fine bristled S/S brush (included in the kit) can become clogged when “brushing, scrubbing or flicking off” the first coating of molten Durafix , before reapplying a second coat. This “flicking off” technique releases trapped oxidation, such secondary brushing creates the strong weld previously discussed. An alternative step to create a sound repair is to S/S brush the top of the now solid weld (oxidation rises to the surface) and then re-weld; both techniques sort of “doing it twice”.

Durafix rods are not recommended for Tig or Mig welding applications. Durafix is not suitable or recommended to weld other non ferrous metals, steel or stainless steel. Please use safety goggles and adhere to all Occupational Health and Safety guidelines when using Durafix and a heat source.