Soldering Al to Cu
- While not an easy operation, it is possible to Solder Aluminum to Copper.
As an Electrician I have had call to perform this a few times on circuit
boards and control panels.
The first thing one must do is to clean both elements very well, and this
means with sand paper till bright, and then with a chemical cleaner.
Then apply a heavy coating of flux, and separately "tin" each element. I.E.
solder each piece alone and let cool.
After cool enough to handle, you must sand or even file off the excess
solder until both fit pieces together cold. This thin coating od solder
will make it MUCH easier to join the elements
After you have tinned and sanded these elements, and they fit tightly; then
you may flux again, and solder together as normal, you will find this will
work, but with some added effort.
FYI from your not-so-local friend,