Place some SOLAR FLUX powder in a container.

Place some SOLAR FLUX in a container

Add alcohol (methanol – methyl alcohol preferred for the best results.)

Mix to a consistency between ‘thin and soupy’ and ‘thick cream’, whichever seems to work best for you. The consistency of the mixture, whither thick or thin, does not affect the operation of the SOLAR FLUX or the quality of the finished weld. Mix only what you are going to need for a few hours or, at most, a day’s work.

Mix to desired consistency

Let the mixture stand for a few minutes while a chemical reaction takes place.

Make sure the metal is free of dirt and grease. Brush the mixture on the back of the joint. Use it sparingly, just enough to get complete coverage. Try to stay within one quarter inch of either side of the joint.

Brush mixture on back of joint

Allow a few minutes for the alcohol to evaporate.

Weld using the same procedure that you would use if you were using a gas purge.

Weld as usual

Good practice dictates that you ALWAYS run and test a sample coupon when changing anything in your procedure.


The thin glass-like residue is chemically inert after welding and adheres tenaciously to the base metal. While this residue is unattractive to the eye, it does not affect the quality of the weld and usually need not be removed. However, if removal is desired, it is easily accomplished with a stainless steel wheel, stainless steel brush or common pickling compounds. Our research indicates that ‘Wonder Gel’, manufactured by Bradford DeRustIt Company, is excellent.

(Note: there are some pipe or tube welding applications where absolute purity and a polished inside surface are required. These include food or beverage lines where subsequent product refining will not take place, medical oxygen lines, computer chip manufacturing air lines, and high service temperature (above 1000°F) steam lines. In these situations we recommend purging instead of SOLAR FLUX so as to avoid a difficult chemical cleaning process.)