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Hi Mental
I've joined aluminium using a special eutectic flux that allow the use of a gas torch to join two pieces of Aluminium. Put the flux on the surfaces heat up and carefully join when the ally melts. I was making aluminium wire seals for vacuum systems. The trick is, you need to use pure aluminium. The other problem is that Aluminium conducts heat away very quickly. Dreadful job. It's hard enough in thin 0.5mm wire to get the heat in to melt the wire let alone some big thick extrusion. The alloys used in the billets they feed into extrusion dies don't weld nearly as well. I've gone back to using 99.99% gold wire, more expensive but much easier to weld
Some eutectic fluxes allow dissimilar metals to be joined. PM me a description of exactly what you want to do including the alloy numbers and thicknesses and strength required. If I don't know, I can find out from a close friend who runs a high tech engineering workshop what if anything you can use to do the job.
cheers
Joe
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