welding in aluminum Smelter Company

You won't be able to solve the arc blow problem unless you can get rid of the high magnetic field, at least while welding but, you already know this. So, other than that, I'd vote for the exothermic welding process.

Brazing of aluminum to copper is difficult due to low melting temperature 1018 F ( 548 C ) of aluminum –copper eutectic and its extreme brittleness. By heating and cooing rapidly , however, reasonably ductile joints are made foe welding copper inserts to aluminum castings. The usual filler metals and fluxes for brazing aluminum can be used, or silver alloy filler wires like Bag – 1 and Bag -1a can be used. if heating and cooling are rapid. Pre-tinning of the copper surfaces with solder or silver alloy filler metal improves wetting and permits shorter time at brazing temperature.

More practical way to braze aluminum to copper is to braze one end of a short length of aluminum - coated steel tube to aluminum and then silver braze the other end of the tube to the copper.

SRIDHAR - ADV. INSTITUTE OF WELDING TECHNOLOGY -CHENNAI -INDIA

Try to use ESAB OrigoMig 3000i, this is the best machine for aluminium welding.

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