Oxy-Acetylene Welding Aluminium – Complete Guide
Many people believe that aluminium can only be welded using TIG or MIG. However, with the right flux, filler rod, and a soft flame, gas welding works excellently – and Dillon is engineered for exactly that level of control.
Aluminium with a soft flame — start with the right kit.
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Dillon gas-welding thin aluminium — soft flame, controlled joint.
Why aluminium is difficult
Aluminium forms an oxide layer instantly when exposed to air. This oxide melts at around 2000°C, while the underlying aluminium melts at just 660°C – and it does not change color as it heats. Without the proper technique, you will burn through the metal before you even realize it has reached its melting point. The solution is a dedicated flux that dissolves the oxide, combined with a flame that delivers precise heat.
Why Dillon works
The torch operates at just 0.5 bar. This produces a soft, concentrated flame with a narrow heat-affected zone – exactly the control that thin aluminium requires. It allows you to maintain the proper working temperature without the excessive heat spikes that cause sheet metal to collapse.
When gas welding works better
With Dillon you can weld aluminium sheet down to 1 mm without it warping.
- Thin aluminium sheet where a TIG welder feels like overkill.
- Cast aluminium – with the right rod and flux.
- Jobs without three-phase power – just acetylene and oxygen.
How to do it
- Clean the joint thoroughly with a stainless-steel brush (used for aluminium only) and degrease the area.
- Mix the aluminium flux with water into a paste. Brush it onto both the joint and the filler rod.
- Set a neutral, soft flame. For thin sheet metal, select a small tip (size 0 or 0.5).
- When the flux turns shiny and fluid, the material is ready.
- Add the correct filler rod (see table).
- Wash off the remaining flux residue with hot water – it is highly corrosive.
Which filler?
| Material | Filler |
|---|---|
| Unknown/mixed alloy, general repairs | Aluminium rod 5 % Si |
| AlMg, marine parts | Aluminium rod 5 % Mg |
| Pure aluminium (99.5 %) | Aluminium rod, pure |
Equipment
- Standard Kit or Pro Kit
- Aluminium flux + the right rod — or Wire & Flux Pack
- Welding goggles with the right shade
Want more step-by-step? See our getting-started guide.
Next step: choose Standard or Pro.
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