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Grounding aluminium PCB substrate

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coppercone2:
aluminum solder is shit, sand it flat, use the proper aluminum solder and ultra smelly agressive flux and scrape it with a sacrificail iron to get some kind of wetting, then sand the nasty oxide off both tinned surfaces, hold them close, reflux, remelt, should hold (poorly), getting it to 'flow' is like convincing a cat to do something (maybe dripping hydrochloric acid on it and washing would work well )

I never got it to 'look nice' its like a bad weld job where you need to sand it afterwards



I kind of wonder how a rivet would work if you put a star washer for it to compress against , something like pop rivet, crimp, star washer, aluminum

flux matters:
https://superiorflux.com/portfolio-item/tensile-strength-testing-3003-aluminum-soldered-lap-joint/

what I like doing with aluminum braze is low strenght frames for filters to put over chassis holes. you glue window screen material into an aluminum frame (you can cut the aluminum flat bar with bolt cutters, arrange it in a shape on a fire brick and braze/solder it together very quickly, since you are putting glue and filter material over it, it does not need to look nice, and materials use is minimal since you are not cutting holes in sheets etc use thicker flatbar so the edge joint has some strenght and cut it on 45 degrees, but I am setup to do this quick with a proxxon mini-saw

i put a rubber gasket under neath I cut out of things like foormat or toolbox mat liner material around the frame.

obviously not a EMI screen

Amper:
Mh, i didnt have any of those problems. The solder i have is used just like normal electronics solder with flux core. It boubles sligtly more but it wets  the surface beautifully and the joint is just as good as with any lead free solder on copper.

What i do wonder though is if doing the entire thing under argon could make flux redundant entirely, in this case it would be possible to do this in the pcb manufacturing process commercially by just drilling half way and setting large bga balls down on the holes to melt later.

coppercone2:
can you post a picture of a beautifully wetted aluminum solder joint, it might make me reinvestigate the process, right now I am totally fed up with it

Amper:
Here you go, some copper i found on the table soldered to a piece of .1mm aluminium drill cladding. Soldered with Rexin 240 using a normal soldering iron, didnt ruin the tip, though i clean it after soldering.

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