In this work, the possibility of welding aluminum parts by self propagating high-temperature synthesis technique is investigated. Metallic compounds (such as sulphates and fluoride compounds) and aluminum are used as the precursor combustion powders to perform the exothermic welding process. Aluminum as a reducing agent reacts with metallic compound to release heat for melting the remained aluminum. A proper flux such as CaF2, MgF2, cryolite, alkali silicates and fluorosilicates suggested to be used to improve the fluidity of produced slag. Weld powder mixture composition have to be controlled exactly since the molten pool adiabatic temperature is highly dependent in composition. So the current work propose an optimum powder composition to form a high quality weld with the lowest aluminum powder consumption, as the most expensive used powder.

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