Oxy-Acetylene Welding Aluminium – Complete Guide

Many people think aluminium can only be welded with TIG or MIG. With the right flux, filler rod and a soft flame, oxy-acetylene works excellently — and Dillon is built for exactly that control.

Why aluminium is difficult

Aluminium forms oxide in air immediately. The oxide melts around 2 000 °C while the metal underneath melts at about 660 °C — and it does not change colour as it heats. Without the right technique you burn through before you see it. The solution is flux that dissolves the oxide, plus a flame with precise heat.

Why Dillon works

The torch runs at only 0.5 bar. That gives a soft, concentrated flame with a narrow heat zone — exactly the control thin aluminium needs. You hold working temperature without the spikes that collapse the sheet.

How to do it

1. Clean the joint with a stainless-steel brush (aluminium only) and degrease.
2. Mix aluminium flux with water into a paste. Brush joint and rod.
3. Set a neutral, soft flame. Thin sheet: small tip (0 or 0.5).
4. When the flux turns shiny and fluid, the material is ready.
5. Add the right filler (see table).
6. Wash off flux residue with hot water — it is 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 the getting-started guide and the short aluminium guide.