Electronics > Repair

Splicing very short AL wires

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coppercone2:
the key is to get the aluminum soldering flux that works

I had nothing but problems but someone at work left and they gave me a remains of a jar that wow it soldered foil like copper (NO BS LIKE mineral oil)

this one looks correct from memory, I would have to go to my shop to check but the container looks right, and my leg hurts right now
https://www.amazon.com/STAY-CLEAN-FLUX-4-OZ/dp/B008FM5JXI
but I have a tiny 1oz bottle. hmm

soldar:
The problem is not only making electrical contact with aluminum but also that there are just a few mm showing and very fragile and quite inaccessible. It's not like I have a long end and can easily handle it. I cannot easily hold, scrape, etc.  I can hardly get in there. If I handle it any more it's going to break and that will be the end of it. Which may be a good thing.

hanakp:
Like I wrote earlier, forget brushing, oil etc. Just get aluminium flux with hydrofluoric acid, then it will solder almost like copper wire.

Psi:
Has anyone tried pointing a TIG torch at some aluminum electronics just with the gas on, then cleaning and soldering the aluminum part?  Does it work well?

5U4GB:
I've never tried it at this (tiny) scale but could you try brazing, a.k.a. "aluminium welding", it?

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