Is this a brand new product?

No. It’s been in use in the private sector for years, but is now being made available to the public.

Is this really considered welding and not tig brazing?

According to the AWS terms and definitions they do not recognize the term tig Brazing. We consulted with them when researching how to define this method . Additionally this is a 2 step process . When welding the steel it does not intermix as in fusion welding and the rod melts at a lower temperature so that leads some to conclude that its brazing but the same does not apply to the second step .When welding the aluminum there is some fusion that takes place and the rod melts at a higher temperature than the aluminum. Since these rods are manufactured as a tig rod and used in the tig welding process it was decided that tig welding was best suited to describe this rod . That being said we do understand that over time new words and phrases become accepted and used by the general public so if the term tig brazing helps people to better understand the process then that’s what’s most important .

Can this be used on applications thicker than 1/4" steel?

Yes. But only by more experienced users that are well acquainted with this product. The thicker the material the more difficult it becomes to maintain a consistent technique and heat temperature. Before using it in a manufacturing production setting, adequate testing should be done to ensure proper weld technique as well as welder qualifications. Safety should always be the main concern for both the welder and the end user.

Is a gas lense and a cup neccessay?

Yes. It’s integral for the best possible coverage and protection to minimize oxidation common in welding aluminum in a DC process. Normally AC is used for aluminum because of the cleaning affect it has, but in this case it’s not optimal for the steel.

How critical is the heat setting?

The recommended temp is a good starting point to gauge yourself. Too low could cause poor adhesion and penetration.

Should I always use new welding materials?

Its recommended at first because many problems can arise from using recycled materials because of previous contamination or exposure to penetrating top coats like galvanizing and other conditions. When first learning its best to minimize any possible contaminants so as to ensure a trouble free experience. After you are very familiar with the product then you might branch out and experiment, only then will you be able to trouble shoot any problems that might arise.

Are top coats and finishes okay after for cosmetics?

Yes. But remember that if you use any caustic or acidic finishes this will most likely affect any future welding repairs to that area, difficult at best. Adequate grinding to remove contamination from top coats are always necessary but more so in this case because the pulsing will most likely entrap contaminants. Standard welding techniques will most likely burn them out.

It seems a bit time consuming, can the process be sped up in a manufacturing or production setting for cost efficiency?

Yes. In most cases it is possible. But results will vary depending upon your individual needs and challenges. Our tech support team may help you devise a strategy that will be most beneficial for you.

Can it be mig welded?

Yes and it has the same chemistry as the tig rod . The benefit is that it is faster and easier to use so it is preferred for production type applications or thin materials like autobody repairs. Also the possibilities are endless since heat settings are a factor then mig pulse can be employed and its full potential can be utilized since this is not recommended when using the tig rod.

Is it available in all areas?

Let us know where you are and will do our best to get it to you. Of course we have no control over shipping costs and government restrictions.

How well does it work on aluminum to stainless?

Very well. Just remember to take all standard preparations and precautions when welding stainless. Remember thin stainless can burn out easily so be sure to use heat sinks and back purge where necessary. Although current products exist, what we have is as revolutionary as our rod. Nothing like it exists.

How well does it work on similar metal combinations such as steel to steel?

Very well, but probably not cost effective. Remember it is not a replacement for standard practice applications. It does not color match well and will not meet the same benefits provided by standard welding rod applications, such as ductility, tensile strength. Manual pulsing is very slow. Where it is exceptional is dissimilar metal combinations, it is very effective since there are relatively few choices or techniques that work especially with such relative ease. Also in locations where budgets are limited, this rod can have multiple uses, and can get you out of a bind where down time is paramount. Think about when a production line must come to a stop for a costly weld repair. Think about the ability to transition from steel to aluminum in numerous fields such as automotive, sport bike, off road equipment, machinery, tooling, the list goes on and on.

What about heavier commercial or industrial applications?

Not recommended. It was never designed for that purpose . For industrial strength applications we recommend using bi metal plates and transitions . They are industrial strength and come in most any combination and application. For custom situations where the welder is limited by the shape, size ,quantity, configuration of weldment then the tig rod or mig wire is advantageous especially for light duty applications. 

Any harmful chemicals?

No. Nothing that you haven’t already been using for years. But always remember to use best shop and standard safety practices such as proper ventilation, protective eye wear and welding gear.

What about bi-metalic embrittlement?

It is generally not a problem for light duty applications such as this since “light duty” implies that it is not going to be used for anything in which bodily injury can occur due to poor welding or anything excessively heavy for which this is not intended.

What about galvanic corrosion?

Generally not a problem as long as some type of protective top coat is applied.

Why do you recommend cold rolled low carbon steel?

It is the easiest to use because it does not require pre heat in thicknesses of ¼ or less, thereby minImizing any problems with coefficient thermal expansion and excessive heat transfer to the aluminum. The higher the carbon content, then preheat and post heat become a factor. Also the tensile Strength in low carbon steel is lower and is a closer match to try to equalize the difference in the two Materials creating a more even balance in the stresses developed from welding. It is also very ductile And helps to create a more successful joint. It is low cost, easy to obtain, easy to use, and generally Meets the needs for this application.

Why do you recommend 6061T6 Aluminum?

It is the best choice for this application. It welds good, is versatile for numerous applications. . The combination of 6061T6 and cold rolled low carbon steel ( .015-.025% max ) are the perfect choice and can be used for most any application. Always be sure to do research or consult a professional to determine your exact needs and technical perimeters.

Why do most people say it can't be done?

That’s not accurate! Most people are not educated on the subject. In reality welding dissimilar metal combinations has been around for a long time. There just was not a lot of demand for it back then. As technology advances and our needs grow so does our demand for bimetallic combinations. For example, the automotive industry currently uses bi metallic combinations to reduce overall weight and increase gas mileage and performance, minimizing strains on limited natural resources. In reality… it is here to stay and its demand will only increase!

Can you use hot rolled low carbon steel?

Yes . But remember that because it is hot rolled it has a heavy barrier of scale due to the manufacturing process . It should be ground clean very well because the scale goes deep , at least .040 and can create a poor bond if not ground properly. It is very soft and is good for this process but we recommend using the steel pre-coat rod/wire because it was designed to deal with that problem . After you pre-coat the steel just grind the newly welded surface to eliminate any scale , oxidation etc. and proceed. This will give you a clean bonding surface and should work well.