How to weld aluminum with MIG or TIG Welder

Learning how to weld aluminum may be hard because it is more challenging to use than steel. Why do we would like to utilize aluminum anyways? Well, aluminum doesn’t break even after turning rock-solid.


Whether it’s metals that are non-heat-treatable such as those containing a small quantity of manganese (Mn) or magnesium (Mg), or heat-treatable metals containing magnesium zinc, silicon aluminum and aluminum with 99% transparency.

“Aluminum could be incorporated into many different permits and the welding procedure is different based on the kind of aluminum that you’re welding.””

Workpieces of aluminum that contain copper or lead additives are always more difficult to weld because they will have a propensity to crack through the welding procedure.

How to weld aluminum with MIG and TIG Welding

Aside from the other sorts of welding plasma welding, gas welding and resistance welding, aluminum welding may be performed with MIG welding and TIG welding.

MIG or Metal Inert Gas welding is just actually a subtype of Gas Metal Arc Welding (GMAW), whereas TIG welding is just another material for Gas Tungsten Arc Welding (GTAW). TIG welding employs a non-consumable tungsten electrode to weld metal. In MIG welding, a consumable wire and shielding gas is fed with a welding gun.

TIG vs MIG Aluminum Welding

The issue arises, when to TIG weld aluminum and also when to MIG weld it. TIG welding can be used when you would like a high quality finish and in scenarios where you can just weld from one side. As an example, you will only weld out of one side when you’re working with pipes or repairing castings.

MIG welding process is utilized for more thicker aluminum pieces. Additionally, it functions at a faster pace, and it is another factor that makes it popular. MIG welding is also useful in producing extensive, non-stop welds. MIG welding uses not as much heat to the metal than TIG welding, which means there’s reduced possible deformation of the alloy if MIG welding is used.

But the most innovative technique of welding is the one where you use pulse arc in conjunction with MIG welding; this approach gives the best outcomes. It increases the control over the molten pool for thin materials, stabilizes the arc and reduces spatters and also the possibility of injury from the welding procedure. This method may be referred to as aluminum arc welding.

Steps of How to weld aluminum with MIG

Aluminum needs some particular changes for welders that are used to welding metal. It has a far thicker metal therefore that the feed cable must be much larger. Aluminum is also a much better flow of heat, therefore welding aluminum needs longer control within the electricity supply and also the feed speed of the electrode.

Choosing a better MIG Welder

A 115-volt welder may take care of aluminum till an eighth of an inch thick (3 millimeters ) with sufficient pre-heat, and a 230-volt machine can weld aluminum that’s a quarter of an inch thickness (6 mm). Select a machine with an output greater than 200 amps if you regularly weld aluminum items.

Selecting the right gas

Aluminum needs a shielding gas with argon in contrast with steel, which typically utilizes a mix of argon and carbon dioxide (CO2). This should not require any new hoses, although you may need to Restore regulators for CO2.

Using the electrodes of Aluminium

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Thinner cable is more challenging to feed, whereas thicker cable requires greater current to melt down. Electrode thickness is particularly critical with aluminum and there’s a very narrow range to think about. The welding electrodes should be less than 1 mm and within .035” of thickness. You should keep in mind that harder alloy requires more electrical consumption.

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